S791 M-38 6R5111121 Steering Gear PDF

20
Insttruction Manua
al
for
Electro--Hydraulic Steering Ge
ear
(RE & FE Series)
剾
Read and keep th
his Instruction Manual & Finished Plan.
FLUTEK, LTD.
Marine Machinery Facto
ory
HanJi 18 Gil 70, Bongsu-myeon n, Uiryeong-gun, Gyeongnam, Republic of Korea
a
(Tel : 82-55-570-5721, Fax : 82
2-55-574-5713)
Service center (CS Team)

192-11, Shinchon-dong, Chang gwon, Gyeongnam, Republic of Korea
E-mail : csmarine@flutek.co.kr
(Tel : 82-55-570-5770,~5, Fax : 82-55-286-5571)
Home page : http://www.flute

ek.co.kr
(Drrawing No. : 00905081F-1)
Installation manual Page 1 of 57 FLU

UTEK Steering gear
SAF
SAFETY
FETY PRECAUTIONS
Before you use the product, you SHALL read this instruction manual and SHALL fully understand
how to use the products. You SHALL also observe the related regulations and rules regarding
safety. To use the product saffely, you SHALL carefully read all Warnings a
and Cautions in this
instruction manual.
Danger : indicates an imminently hazardous situation which, if not avoided, will result in
death, serious injury
i or serious accident.
Warning : indicates a pottentially hazardous situation which, if not avoid

ded, could result in
death, seriouss injury or serious accident.
Caution : indicates a pote

entially hazardous situation which, if not avoide
ed, may result in
minor or mode erate injury.
Notice : signs used to indicate a statement of company policy directlyy or indirectly

related to the safety of personnel or protection of property.
[1] Warnings and Cautions related to operation

This produuct(part) is designed and manufactured in n accordance with
WARNING the specifi
fications of this ship, so it is impossible to
o change specification
after deliv
vered or to equip other ships.
WARNING Never ope

erate the product(part) after you have alco
coholic drink or drug.
Operate th he hydraulic pump and valves in accordan nce with the
WARNING instructionn plate, otherwise the ship can lose the stteering capability
causing se erious accident.
Do not steep on the product(part), hit it, drop it, and
d give strong outside
CAUTION force to it,
t, as one of these actions may cause the fa ailure of work,
damage, oro oil leakage.
Use the saafety equipment to avoid injury when you u operate the
CAUTION
product(papart).
Pay enoug gh attention on handling method to avoid d pinching hands or
CAUTION back problblems that may be caused by heavy weight ht of the
product(papart) or handling posture.
Wipe the oil
o on the floor off completely, as the oil ccreates slippery
CAUTION
conditionss that may result in injuring.
Keep the product(part)
p from dust and rust and pay y the attention to the
NOTICE surroundin ng temperature and humidity when you ttransport or store the
product(papart).
Replacing the seals may be required if you use the product(part) after
NOTICE
long time storage.

UTEK Steering gear
[2] Warnings and Cautions related to installation and removal of the
e product(part)
Turn off th
he power before starting wiring or other w
works related to the
DANGER
electric po
ower, otherwise you can be stuck by an ellectric shock.
Installatio
on, removal, piping and wiring shall be do
one by the certified
WARNING
person.
Make it suure that the power of the hydraulic powerr unit is turned off
and that the
th electric motor has completely stoppedd before starting
WARNING
installatio
on or removal. You must also check the sy
ystem pressure has
dropped to o zero.
Use the sppecified bolts and keep the specified tighttening torque when
you installl the product(part). Usage of unauthorizeed bolts, lack of
CAUTION
torque, orr excess of torque may create problems su uch as failure of
work, dammage and oil leakage.
Clean the threads
t and mounting surface completely y, otherwise you may
CAUTION experience e damages or oil leakage caused by insufffficient tightening
torque, bro
roken seal.
[3] Warnings and Cautions for operation

Keep yourr body off the rotating or moving part such
ch as electric motor,
DANGER actuator or
o connecting rod, otherwise it may resultt in death or serious
injury.
Investigatte the cause immediately if you find some ething wrong such as
WARNING unusual nooise, oil leakage and smoke, and fix it pro
operly, otherwise you
may encou unter damage, fire, or injury.
Use the prroper working oil, and maintain the conta

amination, otherwise
WARNING
it may nott work or be damaged.
Use the prroduct under the specification mentioned

d in the drawings and
WARNING
the specifi
fication sheet.
Make it su
ure that piping and wiring are correct and
d all the connection is
CAUTION tightened correctly before start operating, especiallly if it is the first
run. Otherrwise you may experience injury.
Keep yourr body off the product during the operatio
ons as it may become
CAUTION
hot, in ord
der to avoid a burn.
[4] Warnings related to maintenance

Make it surre that the ship is safety condition such ass at anchoring or at
WARNING
dock beforee starting maintenance, check or repair.
WARNING Never modi
dify the product.
Do not disa
assemble and assemble without approval by FLUTEK. It may
cause troub
bles and failure, or it may not work as speecified. If it is
WARNING
necessary by
b all means to disassemble and assemble le, it shall be done by
an authoriz
zed person.

UTEK Steering gear
Contents
Page
1 General ..................................................... 7
2 Detailed description of main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1 Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Ram and Hydrauliic cylinder ................................. 8
2.1.3 Oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.4 Oil block valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 Construction and name of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.2 Principle of operattion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Continuous control syste

em ..................................... 13
2.3.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Instructions for installation .......................................... 19
4 Instructions for adjustment ......................................... 20
4.1 Preparation ................................................. 20
4.1.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Working oil and filling ..................................... 20
4.1.3 Application of lubrricating oil and grease ....................... 22
4.1.4 aulic pump and electric motor . . . . . . . . . . . . . . . . . .

Centering of hydra 22
4.1.5 Inserting of ram V-packing

V ................................ 23
4.2 Adjustment ............................................... 23
4.2.1 Electric motor starting ................................... 23
4.2.2 Adjustment of serrvo pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.3 Air release in hydrraulic regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

UTEK Steering gear
4.2.4 Adjustment of pum
mp neutral position ........................... 24
4.2.5 Air release in hydrraulic system ............................... 26
4.2.6 Adjustment of con

ntrol box .................................. 26
4.2.7 aximum pump stroke . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment of ma 26
4.2.8 Adjustment of rud

dder angle limiter ............................ 27
4.2.9 Measurement and

d adjustment of rudder turning speed .............. 27
4.2.10 Adjusting test of safety

s valve ................................ 28
5 Steering method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 Normal steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Local steering . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
e
6 Instructions for maintenance ........................................ 32
6.1 General notes ............................................... 32
6.2 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3 Detail of check items .......................................... 35
6.3.1 Normal checks ........................................... 35
6.3.2 Before voyage che

ecks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.3 Periodical checks (at dock or basin) ............................ 38
6.3.4 Check of working oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4 packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of ram V-p 42
6.5 Dismantling and assemb

bling of line filter ............................. 44
6.6 Dismantling and assemb

bling of hydraulic pump ........................ 44
6.7 Dismantling procedures for pintle bearing inspection .................... 49
7 Trouble shooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2 Trouble shooting of stee

ering gear .................................. 52
7.3 Trouble shooting of valvve, pump and electric motor ..................... 55
8 Service net work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

UTEK Steering gear
List of attached drawing
gs
Page
Fig.ラユASSEMBLY OF TILLER AND
A RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
R..........................................
Fig.リユHYDRAULIC CYLINDER 60
Fig.ルユOIL TANK UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig.レユVALVE UNIT (RE SERIE 62
ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE UNIT (FE SERIE 63
Fig.ロユFUNCTION OF OB VALV
VE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fig.ヮユOB VALVE (OB15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
OB VALVE (OB20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
OB VALVE (OB30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fig.ワユSOLENOID VALVE AND

D MANUAL ISOLATING VALVE . . . . . . . . . . . . . . . . . . . . . . 68
Fig.ヰユAXIAL PISTON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fig.ヱユPRINCIPLE OF PUMP WORKING

W .................................... 70
Fig.10ユEXPLODED VIEW OF AXIAL

A PISTON PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fig.11ユSTEERING SYSTEM BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fig.12ユPUMP CONTROL SYSTE

EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fig.13ユPUMP CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
AM OF PUMP CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . .

Fig.14ユCONNECTING DIAGRA 75
Fig.15ユTORQUE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fig.16ユDIFFERENTIAL TRANSFORMER (LVDT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Fig.17ユSERVO PUMP UNIT (RE

EG-090) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
REG-260/500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVO PUMP UNIT (R 79
Fig.18ユRELIEF VALVE FOR SER

RVO PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fig.19ユLINE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
AULIC PUMP AND ELECTRIC MOTOR . . . . . . . . . . . . . . . .

Fig.20ユCENTERING OF HYDRA 82
Fig.21ユAIR RELEASING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fig.22ユADJUSTING PROCEDURE OF SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PACKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig.23ユASSEMBLY OF RAM V-P 85
DURE FOR PINTLE BEARING INSPECTION . . . . . . . . . . . .

Fig.24ユDISMANTLING PROCED 86
Fig.25ユTROUBLE SHOOTING FLOW

F CHART (STEERING GEAR) . . . . . . . . . . . . . . . . . . . 87

UTEK Steering gear
1. General
FLUTEK-Kawasaki Electrica
al Pump Control (Continuous Control) Steering Gear is of the “Rapson
slide type” construction an

nd consists mainly of tiller, ram and ram pin, hyydraulic cylinder, valves
and piping, FLUTEK-Kawasaki axial piston pump and pump control unit.
ed and discharges the oil, through the control b

The hydraulic pump is tilte box and the pump
control unit according to the

t order signal of rudder angle from the steeriing stand.
The ram thrust produced by the pressure oil is transmitted to the tiller arm through the ram
pin and the roller bearingss and converted to the torque of the tiller keyed to the rudder stock
and then the rudder is mo

oved.
The signal of the actual ru

udder angle is directly feed-backed to the steerring stand by means of
the repeat back unit, and when it coincides with the signal of the order rrudder angle, the
rudder stops.
m of the Electrical Pump Control (Continuous C

Thus, in the control system Control) Steering Gear,
the actual rudder angle is directly compared with the order rudder angle
e and the deviation
signal between order and actual rudder angles controls directly the tilting
g angle of the
hydraulic pump.
Therefore the steering gea

ar can obtain the very fast response and the acccurate rudder angle,
and the ship can keep herr heading correctly with a less steering order.
This improves the propulssion efficiency remarkably and consequently can

n save fuel
consumption of the main engine

e highly.
One or two sets of the hyd

draulic pump and electric motor are provided a
and have enough
capacity to operate the ru

udder within the time required by the classificattion society.
For the specifications of th

he steering gear, refer to the PARTICULARS of tthe separate volume.
For the general arrangeme

ent and the hydraulic circuit, refer to the drawings of ARRANGEMENT
and HYDRAULIC CIRCUIT

T of the separate volume.
Installation manual Page 7 of 57 FLUT

TEK Steering gear
2. Detailed descrip
ption of main parts
2.1 Steering gear
2.1.1 Tiller : (Fig. 1)
The tiller made of cast steel, designed and manufactured according to

o the requirements of
classification society is fixed to the rudder stock with the key. On the ffork typed openings of
the tiller, the hardened steel plates are bolted and they contact directlly with the roller
bearing of the ram. Acccording as the roller bearing rotates on this surrface, the linear
movement of the ram is converted to the circular motion of the tiller.
2.1.2 Ram and hydraulic cylinder

c : (Fig. 1 & 2)
(1) The ram is made off carbon steel for mechanical structural use, and the hydraulic
cylinder of nodularr cast iron.
(2) The ram pin is incorrporated into the center of the ram whose surfface has been finished
with high accuracyy, and the rotatory roller bearings (1121) are fittted into the upper and
lower parts of the ram pin and contact directly with the fork typed openings of the tiller
arm. The ram thrust is transmitted to the tiller through the ram p
pin.
m pin is subjected to a strong force, but this can

Therefore, the ram n be dealt with by
employing the matterial of high tensile strength.
The oilless metal iss fitted in the bore of the roller bearing and min
nimize the rotational
friction between th
he ram pin and the roller bearing.
And also lubrication with oil on the bearing is unnecessary.
aulic cylinders that move the two (or one) sets of ram are securely
(3) Four (or two) hydra
installed on the be
ed plate of the hull.
A pair of opposed hydraulic cylinders is connected with the ram g

guide bar (1222) and a
draulic cylinders (in case of four cylinders) is connected with the

pair of parallel hyd
connecting brackett (1231).
The hydraulic pump unit and the electric motor are installed on th
he hydraulic cylinders.
Inside of the each hydraulic cylinder, neck bushing (1205) is provvided, supports the ram
e perpendicular component force of the ram.

and withstands the
Five V-packings (12

210) are also provided inside of the each hydra
aulic cylinder for

TEK Steering gear
preventing oil leaka
age.
The packings are tightened

t by the adapters (1211,1212) and the
e packing gland (1206),
and have superior sealing effect.
ment is indicated by the rudder angle indicator p

The rudder movem plate (4002) fitted
between opposed hydraulic cylinders.
The max. turning angle

a is limited by the rudder angle limit switch
hes at about 36.2
degrees although the

t max. working angle is 35 degrees.
And also the rudde

er movement is mechanically restricted by the sstopper plug (1213) at
the bottom of hydrraulic cylinder (about 37 degrees).
2.1.3 Oil tank : (Fig. 3)
The oil tank is made off cast iron and mounted on the hydraulic cylinde
er.
Inside of the tank, the hydraulic pump, linkage necessary for tilting th
he pump cylinder and
pipes are installed, and

d outside of the tank, pump control unit, servo pump unit and valve
unit are mounted.
The oil filler with air bre

eather, oil filter, oil level gauge, oil level switch,, thermometer, drain
plug etc. are also provid

ded on the tank.
2.1.4 Oil block valve : (Fig

g. 4, 5 & 6)
(1) Function
Starting up one pu
ump only provided that two or more pumps are installed and also
piping connection is
i ready for parallel running of the pumps, delivvered pressure oil from
the running pump will not actuate ram, but merely drive the idle pumps in their reverse
direction.
The oil block valve is a provision for preventing reverse driving off the idle pump.
The oil block valve consists mainly of main spool, spring and valvve casing having ports
AV, BV, AC, BC.
(2) Operation : (Fig. 5)
Right oil block valve

e:

TEK Steering gear
As the solenoid con
ntrol valve is energized, pressure oil delivered ffrom running pump
reaches the right end

e of main spool through a hole of valve casin
ng, moves the main
spool to the left ag

gainst spring and pass AV/AC and BV/BC are op
pened. Then the
pressure oil from pump

p is distributed to the hydraulic cylinders an
nd actuates on the
ram.
Left oil block valve :
As the solenoid con

ntrol valve is de-energized, no pressure oil is su
upplied to the right
end of main spool and valve is in the position where ports AV and
d BV are by-passed
and AC and BC is closed

c as shown in the left figure.
m running pump as well as hydraulic cylinders is stopped at the valve

So pressure oil from
and no pressure oiil is applied on idling pump.
Idling pump, there

efore, will not be driven in its reverse direction.
The solenoid contrrol valve is energized after a few second later th

han the starting of
electric motor (afte

er the electric motor reaches the rated revolutio
on) by means of timer.
Therefore electric motor

m can be started under low load condition due to the pressure oil
from cylinder being

g not applied on the pump.
Also the solenoid control

c valve has the following functions in the Electrical Pump
Control (Continuou
us Control) Steering Gear :
Ꮿ At the operation of
o rudder limiter, steering gear can be instantan
neously stopped by
being “OFF” condittion.
Ᏸ At the failure of co
ontrol source, steering gear can be automatically stopped by being
“OFF” condition.
As well as the main spool

s and spring, the safety valve, the spring lo
oaded check valve for
replenishing the hydrraulic cylinder are integrally mounted on the va

alve casing and the OB
valve is installed outsside of oil tank as a part of valve unit.
2.2 Hydraulic pump
2.2.1 Construction and na

ame of parts : (Fig. 8)

UTEK Steering gear
The hydraulic pump is a variable displacement axial piston type, availa
able up to a high
400 kgf/cm2}, compact and light, and shows high volumetric and
pressure of 39.2 MPa {4
mechanical efficiencies without influenced by pressure range.
The pump is installed in

nside of the oil tank by means of the bolted flange and direct-coupled
through the flexible cou

upling to the electric motor outside of the oil ta
ank.
The pump consists mainly of the cylinder (151) fitted in the cylinder ccasing (202), the seven
piston sub (NO. 123-pisston, NO. 121-connecting rod, etc.) being in recciprocating motion in
nder, the driving shaft sub-group which transmits power to the pump,
seven bores of the cylin
pport the driving shaft, the bearing casing (201)), the front cover
the bearings which sup
(251) in which oil seal (103)

( is provided, the valve cover sub-group.
The cylinder (151) is gu

uided by the center rod (161) and rotated on th
he valve plate (171)
fitted on the valve cove

er (253). As contact surfaces of the cylinder and
d the valve plate are of
the spherical constructiion, self-centering can be obtained when the cyylinder is rotated.
The driving shaft (101) is supported by the bearing casing (201) throu
ugh the roller bearing
(104) and tapered rolle

er bearing (111).
The cylinder casing (20

02) is supported by the two needle roller bearin
ngs(205).
02) together with the cylinder (151), therefore, can be tilted around
The cylinder casing (20
the axis of the needle roller

r bearings (205) by moving the pin of the ccylinder casing by
means of pump controll unit.
Rotating motion of the driving shaft (101) actuated by an electric mottor is transmitted to
the cylinder (151) throu

ugh the connecting rod (121), the cylinder (151
1) is accordingly
rotated around its cente

er in the synchronous speed of the driving shafft (101).
In the case the cylinderr (151) is located in the oblique position againsst the driving shaft
centre, the piston (123) reciprocates in the cylinder bore relatively to the cylinder.

UTEK Steering gear
The valve plate (171) having
h a suction-and a delivery-port to change over oil with the
reciprocating motion off the piston is provided between the cylinder (1

151) and the valve
cover (253). The valve plate (171) and the cylinder (151) are in optim
mum hydraulic balance
during pump running.
Oil to be delivered from

m and sucked in the pump cylinder passes throu
ugh the passages in
the valve cover (253), the

t cylinder casing (202) and the pipe flange (2
254), then it is
transferred to the pipe outside of the pump.
Suction valve unit (No.2

280-suction valve cover, No.281-poppet, No.283-spring etc) serves
for replenishing oil auto

omatically from the oil tank during pump runnin
ng.
2.2.2 Principle of operation : (Fig. 9)
The driving shaft (101) of the pump is driven by the electric motor thrrough the flexible
coupling.
Rotating motion of the shaft is thereafter transmitted to the cylinder tthrough the piston sub
as described in foregoin
ng sub-section.
Referring to the section

nal views of the pump in Fig. 9, principle of pum
mping action is
illustrated.
Middle and bottom of the right figures are the sections perpendicular to the left figure, and
direction of rotation is assumed

a as clockwise viewed from the shaft en
nd.
In the case that the tiltting angle of the cylinder is equal to zero, i.e. th
he axis of the cylinder
aligns with that of the driving

d shaft as shown in top and middle figure
es, any relative motion
d the cylinder bore with pump rotation will not occur, no oil will
between the piston and
consequently delivered. No delivery from the pump with its rotation as described above is
called as neutral.
In the case that the cyllinder is tilted around its tilting axis as shown in
n the bottom figure,
the pistons below X-Y liine are going to withdraw from the bottom of tthe cylinder bore with

UTEK Steering gear
their clockwise rotation and suck oil through the port “b” of the valve plate, and the pistons
above X-Y line are going to approach to the bottom of the cylinder bo
ore and discharge oil
through the port “a” of the valve plate.
Displacement per revolution depends on the tilting angle of the cylind

der from its neutral
position and reaches itss maximum value at the tilting angle of 27 degrees (the maximum
tilting angle is adjusted

d according to the type of steering gear).
If the cylinder is tilted to

t the reverse direction of the bottom figure, th
he reverse action of
t cylinder bore will take place, accordingly the pistons below X-Y
the pistons relative to the
line will discharge oil th

hrough the port “b” and the pistons above X-Y lline will suck oil
uch being the case, direction of flow can be changed without altering
through the port “a”. Su
the direction of rotation

n of the driving shaft.
Relation of direction be
etween oil flow and tilt of the cylinder is shown in the table.
The valve plate (171) in Fig. 8 having two ports “a” & “b” in Fig. 9 is of importance for
changing over oil as we

ell as preventing oil leakage through the cylinde
er end.
2.3 Continuous contro

ol system
2.3.1 Operation : (Fig. 11 & 12)
The signal of order rudder angle is compared with the feed-back signa
al of actual rudder
angle at the steering sttand and its deviation signal is transformed into
o the pump control
signal in the control boxx.
By this signal, the torqu

ue motor is driven and the hydraulic pump is tilted through the
hydraulic regulator. The

e oil is consequently discharged from the hydra
aulic pump and
applied to the hydraulicc cylinder, and the tiller will be rotated through the ram and the ram
pin.

UTEK Steering gear
The torque motor is sto
opped when the pump tilting angle reaches tha
at corresponding to the
pump control signal beccause the electric signal of pump tilting angle is feed-backed to the
control box by the diffe

erential transformer (LVDT) in the pump controll unit.
In proportion as the acttual rudder angle nears to the order angle, the
e hydraulic pump
returns to neutral position due to the reverse rotation of torque motorr and the tiller stops
when the actual rudderr angle coincides with order angle and oil is nott discharged from the
hydraulic pump because the electric signal of actual rudder angle is fe

eed-backed to the
steering stand by the re

epeat back unit.
2.3.2 Construction :
(1) Control box :
This box is supplied by the autopilot manufacturer in order to transform the deviation
ering stand into the pump control signal and drive the torque motor.
signal from the stee
It also controls the solenoid

s control valve when the rudder angle liimiter is operated.
(2) Pump control unit : (Fig. 13)
This unit consists off hydraulic regulator, torque motor and pump tiilting angle indicator
plate, differential tra

ansformer (LVDT).
The pump control siignal from control box drives the torque motor and the hydraulic
pump is continuously controlled through the hydraulic regulator.
nsformer (LVDT) is also provided in order to fee

The differential tran ed-back the electric
signal of the pump tilting

t angle to the control box.
The pump control knob

k for local steering is usually mounted on the pump control unit
and used when the autopilot system is failed or steering gear is ad

djusted.
ator : (Fig. 13)

(2.1) Hydraulic regula
The pilot spool (202)

( of the hydraulic regulator is moved by the
e torque motor (101).
n (403) connected to the cylinder casing of hydraulic pump

The servo piston is also

UTEK Steering gear
moved by the he
elp of pressure oil generated from the servo pu
ump and the oil is
discharged from the hydraulic pump.
Operation of reg
gulator is explained by referring to Fig.12.
The rotor shaft of

o torque motor is connected to the pilot spool (202) and rotational
movement is con
nverted to the stroke of spool.
The servo piston

n (403) is also connected to the tilting pin of pu
ump and the
movement of pisston is transmitted to the pump.
While, the servo piston (403) is connected to the feed-back sle

eeve (203) through
feed-back lever (303)

( and the stroke of piston is feed-backed tto the feed-back
sleeve.
When the pilot spool

s (202) is controlled to “pushing in” directio
on (rightward in the
e oil from servo pump is lead into the chamber A (oil passage from
figure), pressure
“a” to “b” is clossed). The chamber B is opened to the drain thro

ough oil passage “b” to
“c”. Accordingly the servo piston (403) moves rightward and sttops at the position
where the feed-b

back sleeve (203) closes the oil passage “b” to the drain, that is, the
servo piston stop

ps at the position corresponding to the stroke o
of pilot spool (202).
03) tilts the pump in the same direction and by the same angle in
Servo piston (40
accordance with the movement of pilot spool (202).
When the pilot spool

s (202) is controlled to “pulling out” direct-iion (leftward in the
figure), pressure
e oil is lead into both chamber A and B. As presssure receiving area of
chamber B is larger than that of A, servo piston (403) moves le

eftward and stops at
the position whe

ere the pilot spool stops. At that position the oill passage from “c” to
the drain opens to chamber B and the oil passage from “a” to ““b” is closed.
Servo piston (40

03) tilts the pump in the same direction and by the same angle in
accordance with the movement of pilot spool.
Also the spring (207

( & 208) is provided in order to keep the pu
ump at neutral position
(Tilting angle 0 degree)

d when no force is given to the pilot spool (202). This spring

UTEK Steering gear
returns the pilot spool (202) to the neutral position when the ccontrol source of torque
motor is failed and the pump also returns to neutral position.
Note : Neutral position has been adjusted and set the adjusting pin (302) before
delivery. Do not attempt to adjust the regulator at field.
(2.2) Torque motor (Fig. 15)
Torque motor is provided in order to control the pilot spool and

d consists mainly of the
frame (1) where

e the stator (11) is mounted, the rotor with the spider (13) and
magnet (12) fixe

ed to the rotor shaft, the stopper with lever (3)) and bolt (7), the
w pump tilting angle indicator etc. and installed on the casing of

name plate (5) with
hydraulic regulattor.
(2.3) Differential Tran

nsformer LVDT (Fig. 16)
LVDT is provided
d in order to detect the movement of pilot spoo
ol and feed-back the
electric signal off the pump tilting angle to the control box.
LVDT consists off the case (2) with coil (9), the spindle (11) and
d core (10) connected
to the pilot spoo

ol of regulator etc. and is mounted on the casing of regulator.
(3) Servo pump unit (Fig. 17)
Servo Pump Unit is provided in order to supply the pressure oil to hydraulic regulator
and OB valve and mounted

m on the oil tank.
The servo pump is coupled

c to the electric motor through flexible coupling and started
before main pump/m

motor.
(4) Relief valve for servvo pump (Fig. 18)
Relief valve is moun

nted on the manifold of valve unit in order to ad
djust the servo
pressure. Adjusting pressure is 1.8 - 2.0 MPa {18-20kgf/cm2} and set before delivery.
(5) Line filter (Fig. 19)
The working oil flow

wed from the inlet of the filter by the servo pum
mp is filtered while
passing through the

e filter element from inside to outside and reach
hes the outlet, then

UTEK Steering gear
actuates the hydrau
ulic regulator and OB valve.
The filter consists off the filter head (1) with an visual indicator (8) & by pass valve (relief
valve) (11), filter ca

ase (2), filter element (5), etc.
(5.1) Indicator
During the filtrattion, the filtering surface is contaminated by the accumulated dirt in
the oil and the differential

d pressure between the inlet and the o
outlet is increased,
b effect on the servo pump and hydraulic equipments. So the

which causes a bad
indicator is proviided in order to know the degree of clogging co

ondition (differential
pressure) before
ehand.
When the indicator ring (red) is floated up to the white level in the column (highest
position), the diffferential pressure is 0.2 MPa {2kgf/cm2}. In th

his case, the filter
element (5) musst be cleaned or replaced.
However it will be
b desirable to clean when the ring reaches the
e middle position in
height (the differential pressure is 0.1 MPa {1kgf/cm2}) since a

after then the ring will
osition comparatively in short time.

reach the top po
(5.2) By-pass valve (R

Relief valve)
When the filter element

e (5) is not cleaned although the indicato
or shows the clogging
condition (highest position), the element (5) may be damaged since the pressure on
ncreased due to the less of allowable flow. The by-pass valve (11) is
element (5) is in
provided in orde
er to prevent the damage of hydraulic equipmen
nts, and the valve is
t differential pressure is 0.29~0.31 MPa {3.0~3.2kgf/cm2}, then a

operated when the
part of flow reacches the outlet directly without passing through

h the element (5).
(6) Repeat back unit
ed mechanically to the tiller in order to feed-ba

This unit is connecte ack the electric signal

UTEK Steering gear
of actual rudder ang
gle to the steering stand.
This unit is supplied

d by the autopilot manufacturer.
(7) Rudder angle limite

er
Rudder angle limiterr is provided in order to stop the movement of steering gear
instantaneously by cancelling
c the electric signal to torque motor an
nd de-energizing the
solenoid valve conse

equently OB valve is unloaded when the steerin
ng gear will be moved
by any reason over than the max. working angle (35 degrees on e
each side).
The limit switches are

a mounted between opposed hydraulic cylinde
ers and operated by
the movement of ra
am.

UTEK Steering gear
3. Instructions forr installation
The steering gear will be shipped

s in sub-assembly groups.
In this case, special care should

s be taken to keep safe from injuring everry parts, in particular
the sliding surfaces of tille

er, ram, ram pin, roller bearing and the gauges..
The tiller is usually installe

ed on the rudder stock before launching. The h
hydraulic cylinders are
then installed on the bed plate of the hull. The installation of the importa
ant components such
as cylinder etc. should req

quire centering adjustment and facing-up with tthe liner put on the
bed plate.
For smooth operation and correct rudder angle, the installation should be
e strictly carried out in
accordance with the relative positions and dimensions of each parts. Forr easy installation, the
main component parts wh

hich go together are applied with match marks and knock-pin holes
before being dismantled and

a despatched from our works.
The hydraulic cylinder is securely

s bolted to the bed plate and each cylind
der foot is provided
with the thrust receiver (sstopper and cotter).
hipped after bending and cleaning (by pickling, flushing and corrosion
The hydraulic pipes are sh
preventing) of pipes are carried out and each flange is applied with blind
d plugs at our works.
Prior to filling with oil, che

eck thoroughly the cleanliness inside the oil tan
nk, hydraulic cylinder
etc.
Until the basin trial of the steering gear, cover the surface of the ram witth cloths for preventing
the adhesion of slag and impurities.
Since the steering gear ro

oom is especially subjected to hard vibration, ea
ach bolt is applied with
stoppers for preventing looseness and the hydraulic pipe is secured to th

he steering gear bed
plate by pipe bands.
When the installed steerin

ng gear is painted aboard ship, care should be taken that machined
sliding surfaces are not pa

ainted over but rather coated with lubricant or g
grease for
preventing paint adhesion

n.

UTEK Steering gear
4. Instruction for adjustment
a
When satisfied that the tiller,

t ram, hydraulic cylinder, oil tank, electricc motor, valves, pipes,
repeat back unit etc. are correctly

c positioned, make operational prepara
ation and adjustment in
the following manners.
4.1 Preparation :
4.1.1 Wiring :
Connect the electrical parts

p of control box, steering gear terminal boxx to which torque
onnected, solenoid controlled valve, rudder ang le limiter, repeat back

motor and LVDT are co
unit etc. in accordance with the instruction manual of autopilot manuffacturer.
4.1.2 Working oil and fillin

ng
(1) Working oil :
The working oil app

plicable should be pure mineral oil. Use of vegettable oil is strictly
prohibited because the pump function is spoiled due to deposits.
The highly viscous hydraulic

h oil which has additions of antifoaming
g agent, anticorrosive
agent etc. is genera

ally recommended for working oil.
o viscosity is 10 cSt ~ 1000 cSt and the range of the operating

The suitable range of
temperature is limite
ed to -20୅
୅ ~ 80 ୅ due to oil seal, 0-ring etc. Further, as the
deterioration of oil becomes

b excessive beyond 65 ୅, it is desirable
e not to exceed 60୅.

UTEK Steering gear
<suitable range of viscosity and temperature>
High viscosity limit

1000
750
500
High temperature limit

400
Low temperature limit

300
200
viscosity mm 2/s (cSt)
150
100
75 Optimum
50 working range
40
30
25
20
15
10
9 Low viscosity limit
8
7
6
°C -30 -20 -1
10 0 10 20 30 40 50 60 70 80 90 1
100 110
°F -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
The hydraulic oil havving the following properties has widely used fo
for the steering gear
and is recommendable for working oil.
Kinematic viscosity Flash Pour

Grade Viscosity
mm2/s point Point
(Viscosity grade) index
{cSt} (at 40୅) ୅ ୅
ISO VG68 61.2 to 74.8 incl. Min. Min. Max.
ISO VG56 Over 50.6 to 61.2 excl. 95 200 -20
Caution :
1. The oil must be dealt with carefully not to allow dust and other impurities to mix.
o different brands shall be allowed by any means.

2. No oil mixture of
3. The working oil for the use especially in cold regions shall be a
asked to the oil maker
and our works.
Necessary quantityy of the oil is indicated in the drawing of ARRAN

NGEMENT.

UTEK Steering gear
(2) Filling hydraulic systtem with working oil :
When working oil is filled in hydraulic system, a filter of 200 mesh or over should be
applied for preventin

ng foreign matters and dust.
͛ Fill the hydraulic cyylinder with oil little by little through the oil fille
er at the upper part of
hydraulic cylinder. In this case, air vent valve and cylinder stop vallve should be
thoroughly opened.
͛ Fill the oil tank with

h oil through the upper filler up to the visible upper limit of the oil
level gauge.
4.1.3 Application of lubrica

ating oil and grease :
Since the roller bearing and each joint portion of the steering gear a
are provided with
oilless bearing and oiil-impregnated metals respectively, it is not neccessary to lubricate
with oil or grease in normal

n cases.
However application of oil or grease is required at installation for ru

ust prevention.
͛ Apply grease to the

e sliding parts of the lever.
͛ Fully apply working

g oil to the ram surface.
͛ Slightly apply greasse for rust prevention to other machined surfacces (especially to the
roller bearing, hard

dened steel plate and ram guide bar).
4.1.4 Centering of hydraulic pump and electric motor : (Fig. 20)
Poor centering will cause

c over-heating, wear, noises and vibration of the bearing of
hydraulic pump and electric motor, oil leak from the oil seal, wear of the coupling etc.
Correct centering sh
hould be checked in the following manners.
(1) Parallel error :
As shown in Fig. 20,

2 keep a suitable clearance between the coup
pling faces, install a
dial gauge on the

e coupling of the electric motor and let touch itss pointer to the
coupling of the pu
ump.
(2) Inclination Error :

UTEK Steering gear
Measurement will be performed as mentioned above, however ttouch the dial gauge
pointer to the point near the outer face of the coupling of the pu
ump.
The permissible to
olerances of the parallel error and inclination error shall be adjusted
within the range shown

s in Fig. 20.
4.1.5 Inserting of ram V-p

packing : (Fig. 23)
The Ram V-packingss are inserted at delivery from our works.
If not, it is necessarry to insert them before the ram is moved.
After the confirmatio

on that the ram and packing gland involve no d
dust and impurities, fit
the packings.
The detailed insertin

ng method is referred to item 6.4.
4.2 Adjustment :
After the preparation off each part has been finished, operation and ad
djustment will take
place by means of the pump

p control knob in the steering gear room.
ace carefully, open the stop valve and close the air vent valve.
Clean each sliding surfa
4.2.1 Electric motor startin

ng :
In the first place dissconnect the control box from electrical power.
Before starting the electric

e motor, rotate the hydraulic pump by ha
and (5㨪10 turns) to
circulate hydraulic oil

o in each part of the hydraulic pump.
After confirmation of
o the pump tilting angle being roughly in neutrral by means of the
tilting angle indicato

or plate of the pump control unit, start the elecctric motor.
g direction of hydraulic pump and check for oil leakage from the front
Confirm the rotating
cover of pump and abnormal vibration.
(The rotating directiion is indicated in the drawing of ARRANGEMEN

NT and on the bodies
of oil tank and electtric motor.)
4.2.2 Adjustment of servo

o pressure : (Fig. 4 & 18)
The servo pressure supplying to the hydraulic regulator should be adjusted to 1.8 ~ 2.0
m2} (the green-colored range on the dial plate o

MPa {18~20 kgf/cm of the pressure gauge)

UTEK Steering gear
by the relief valve mounted
m on the manifold of valve unit.
However it is unneccessary to re-adjust the servo pressure onboard

d, since it has been
adjusted at our worrks.
If the adjusted presssure should be the different value from the abo
ove at a daily check,
adjust it according to
t the following procedure.
Remove the cap nutt (3-10), loosen the lock nut (3-6), and adjust tthe pressure by
turning the adjusting screw (3-2).
Turn the screw clockkwise, and the pressure rises, and vice versa.
After the adjustmen

nt, tighten the lock nut securely. (For the sectio
onal arrangement of
the relief valve, refe

er to Fig. 4 & 18
4.2.3 Air release of Hydrau

ulic regulator : (Fig. 13)
Residual air in the servo

s piston cylinder of the hydraulic regulator sshould be released
through the air ventt plug fitted on top of flange (409).
Open the air vent plug, and turn the pump control knob to the righ
ht and left alternately
until the bubbles do

oes not come out.
4.2.4 Adjustment of pump

p neutral position :
The pump neutral position

p is adjusted before delivery and it need not to be re-adjusted
on board. However if necessary, the pump neutral position can be adjusted in
accordance with the

e following procedure such as the pump, the re
egulator, the torque
motor, the LVDT etcc. are re-assembled by any reason.
(1) Hydraulic pump
1. Stroke fully the tiilting lever (Fig.3-1681) together with the pump
p to the direction of
hydraulic regulattor.
2. After installing the power lock (Fig.3-1741) at the end of servo piston (Fig.13-403),
push the piston into the tilting lever.
Then connect the piston and the lever by tightening the powerr lock (Tightening
n Fig.3).
torque is listed in

UTEK Steering gear
3. By measuring the
e length between the end of piston and the cassing of hydraulic
regulator, put the pump in neutral position.
(The length is listted in Fig.13.)
(2) Hydraulic regulator
1. Disconnect the co
ontrol box from electric power. Push the manua
al button of the
solenoid valve forr unloading device and lock it by means of lock nut.
2. Start the electric motor.
3. If the ram is movved large, grab the adjusting pin (Fig.13-302) w

with large monkey
spanner (about 30
00 mm), and turn to the right or left slightly to
o find where the ram
stops. Adjust it in order that the ram movement is less than abo
out 0.5 degrees/min.
at the rudder ang

gle of zero degree.
Don’t loosen set bolts

b (Fig.13- 316) of the adjusting pin before tthe adjustment.
4. If set bolts of the

e adjusting pin are loosened, tighten the three sset bolts to 6.9 N㨯m
{70 kgf㨯cm} unifo

ormly by using torque wrench, then turn the ad
djusting pin to adjust
to zero position.
(Note) Set bolts (Fig.13-

( adjustment of
316) must NOT be tightened after the a
adjusting pin.
(3) Torque motor
1. Insert the rotor (Fig.15-12 and -13) into the rotor shaft (Fig.13--103).
2. Install the frame (Fig.15-1) without the name plate (Fig.15-5) sso that its receptacle
(Fig.15-6) becom
mes in the direction of port or starboard side.
3. Insert the clamp element (Fig.15-2) and flange (Fig.15-10) into the rotor. (Direction of
rotor is referred to
o Fig.13.)
ever (Fig.15-3) on the flange and lock it with flange by means of bolt
4. Put the stopper le
(Fig.15-4).
5. Fit the name platte and knob. (The direction is shown in Fig.13.))
(4) Differential transforrmer (LVDT)
1. Adjust the length

h so that the distance between the end of pilot spool (Fig.13-202) and
the edge of core (Fig.16-10)

( is 89±0.2mm.

UTEK Steering gear
4.2.5 Air release in hydrau
ulic system : (Fig. 21)
It is not enough to fill

f the hydraulic system with hydraulic oil at pre
eparation (When the
pump is tilted after starting, its abnormal noises prove that a greatt amount of air is still
left in the system.) In

I order to expel air in the system, push the m
manual button of the
solenoid control valvve and lock it by lock nut and operate the steerring gear slowly with
nob to “Port” and “Starboard” sides alternately (up to near 30

the pump control kn
degrees in both dire

ections) and open the air vent valve on the upp
per part of the
hydraulic cylinder off the pressure side (ram-drawing side).
Keep on doing this work

w until the intermittent movement of ram iss finished and smooth
movement begins.
In this case the hyd

draulic pump will be started one by one.
Care should be take

en to the oil level of oil tank and replenish the w
working oil if
necessary.
Note : 1. Don't open

n the air vent valve on the cylinder where ram is pressed.
e opened, the air that has tried to expel will be sucked in again.
If it will be
2. Before exp
pelling the air, don't run the hydraulic pump forr hours.
4.2.6 Adjustment of contro

ol box :
Since the control bo

ox is supplied by the auto-pilot manufacturer, re
efer to its instruction
manual for its detaill. The adjusting items are as follows.
(1) Zero adjustmentt
(2) Adjustment of maximum

m tilting angle of hydraulic pump
(3) Adjustment of proportional

p band
(4) Adjustment of ru
udder angle
4.2.7 Adjustment of maxim

mum pump stroke : (Fig. 13 & Fig. 15)
Having finished adju

ustment of item 4.2.6 “Adjustment of Control B
Box”, adjust the
position of the mech

hanical tilting stopper of the pump control unit..

UTEK Steering gear
Loosen the lock nutt, set the bolt (Fig. 15-7) to the position 2ί3mm
m from the maximum
tilting position of the

e stopper lever (Fig. 15-3), and then tighten th
he lock nut.
This adjustment serrves to limit the maximum tilting angle during tthe local steering.
Note : In this adjusttment, prevent the stopper lever (Fig. 15-3) fro
om striking this bolt
(Fig. 15-7) du
uring the normal steering without fail.
Also, during the

t local steering, don't strike the bolt (Fig.15-7
7) hardly with the
lever.
4.2.8 Adjustment of rudde

er angle limiter :
Set the limit switch position of the rudder angle limiter at 36.2degrees͟ Confirm that the
OB valve becomes unloaded

u (solenoid valve is de-energized), the h
hydraulic pump returns
to its neutral positio

on and the steering gear stops, when the actua
al rudder angle reaches
this limited angle. Then

T give an order of the opposite side to confirm that the OB valve
oaded (solenoid valve is energized), the hydraulic pump is tilted, and

becomes again onlo
the steering gear is moved.
And also limit the max.

m order rudder angle of auto pilot so that the
e max. actual rudder
angle is about 35.5d

degrees.
4.2.9 Measurement and ad

djustment of rudder turning speed :
(1) Normal steering :
ear is tested to be capable of putting the rudder over from 35

͛ The steering ge
degrees on eithe
er side to 30 degrees on the way to 35 degreess on the other side in
28 seconds with the vessel running ahead at max. speed.
͛ Correct adjustm
ment has been finished before delivery from ourr works.
If something unssatisfied with the requirement of classification ssociety will be found,
adjust the max. pump tilting angle again.
͛ For special requ

uirements, adjustment has been made to satisfyy its specifications.

UTEK Steering gear
(2) Emergency steering (in case of two pumps parallel running) :
The steering gea

ar is tested to be capable of putting the rudder over from 15 degrees
on either side to
o 15 degrees on the other side in 60seconds witth the vessel running
ahead at half speed or 7 knots (or 8 knots), whichever is greatter. One pump is used
in emergency ste
eering.
4.2.10 Adjusting test of sa

afety valve : (Fig. 22)
The safety valve lim

mits the max. pressure of the hydraulic system and releases
ect the system against

abnormal high presssure produced in the hydraulic system to prote
abnormal load acting on the rudder.
The adjusting presssure has been set at the adjusting pressure shown in PARTICULARS
before delivery from

m our works. Re-adjustment is not required accordingly.
However, it is nece
essary to confirm the operation on board togeth
her with the pressure
test of the hydraulic pipes, gaskets etc., whose procedures are ass follows :
(1) Preparation :
The safety valve test

t will be carried out by means of the pump ccontrol knob
(Local steering).
͛ Disconnect the co
ontrol box from electrical power.
͛ Push the manual button of the solenoid control valve and lock it by means of lock
nut.
Depending on the
e safety valve subject to confirmation, the hydrraulic pump and the
isolating valve or stop valve shall be operated as shown in Fig. 2

22.
(2) Safety valve operration :
͛ Start the electric motor and hydraulic pump and operate the ste
eering gear by the
nob.
pump control kn
͛ When the rudderr angle is over 35 degrees, move the rudder slo
owly.
Since the ram re

eaches the stopper at the bottom of the cylinde
er, the pressure will

UTEK Steering gear
rise.
Turn the handle the

en until the pump tilting angle comes near 1/2 o
of the design max.
pump tilting angle. Under this condition, confirm the adjusting pre
essure of the safety
valve by observing the

t movement of the pointer of the pressure ga
auge. (The adjusting
pressure is marked with red on the dial plate of the pressure gaug
ge.)
͛ The operation of th
he safety valve shall not exceed 30 seconds at a time because the
electric motor mayy cause burning.
(3) Adjustment of safetty valve :
If the adjusting presssure of the safety valve is different from the d

designed one, adjust it
in the following man

nners :
The assembly sectio

on is shown in Fig. 6.
͛ Remove the safety valve cap nut (3-10) and loosen the lock nut (3-6).
͛ Adjust the pressure

e by turning the adjusting screw (3-2).
Pressure will rise if sccrew is turned to right and pressure will drop iff turned to left.
͛ After the adjustmen

nt, fix the lock nut and put the cap nut as origiinal.
When confirming the

e safety valve, check for oil leakage and abnorm
mality in each part of
the steering gear.
After finish of the tesst, put the stop valve, isolating valve, solenoid ccontrol valve, pump
control knob etc. to the

t original condition.

UTEK Steering gear
5. Steering metho
od
The steering gear can be ope

erated by the following methods assuring corre
ect and easy handling
and changing :
(1) Automatic steering by rem

mote control system in wheelhouse
(2) Hand steering by remote control system in wheelhouse
(Follow up control / Non-follow up control)
(3) Local steering in steering

g gear room (by the pump control knob)
5.1 Normal steering :
The normal steering is made

m by the above-mentioned method, (1) or (2).
For details, refer to the Instruction Manual of the autopilot maker beca
ause the contents are
different depending upo

on the remote control system in the wheelhousse (bridge).
The steering gear can be

b operated with all hydraulic cylinders and com
mbinations of hydraulic
pumps in order to meett with the requirements of classification society..
Also changing-over of th
he hydraulic pump can be done by the remote control of electric
motor.
The rudder angle can be

e freely controlled by the order signal of the re
emote control system
from 35 degrees on eith

her side to 35 degrees on the other side.
Precautions :
1. Correctly operate the

e hydraulic pump and valves in accordance with
h the instruction plate.
5.2 Local steering :
In failure of the control system in the wheelhouse (bridge) or during the adjustment
operation of the steering gear, the steering gear can be operated by th

he pump control knob
of pump control unit mo

ounted on the oil tank in the steering gear room
m.

UTEK Steering gear
The steering gear is con
ntrolled by the following procedure.
(1) Preparation
(1.1) Disconnect the

e control box from electric power.
(1.2) Push the manu

ual button of the solenoid control valve for unlo
oading device and lock
it by means of lock nut.
(2) Operate the steering

g gear by turning the pump control knob by wa
atching the pump
tilting angle indicato

or plate and rudder angle indicator plate.
(3) When the steering gear

g reaches the desired angle, release the pum
mp control knob. The
knob and the hydrau

ulic pump will return to the neutral position and
d steering gear will
stop automatically.
Precautions :
1. Correctly operate the hydraulic pump and the valves in accordan

nce with the instruction
plate.
2. Don't operate the

e steering gear over max. working angle (35 de
egrees) because the
rudder angle limite

er is not actuated in local steering.
3. Reduce the ship's speed to half of the max. service speed or 7 kknots (or 8 knots)
whichever is greatter in case of the failure of pipings, and so on.

UTEK Steering gear
6. Instructions forr maintenance
In order to ensure good ope

eration and long life of the steering gear, follow
wing maintenance and
checks should be carried ou

ut.
6.1 General notes :
(1) Filling hydraulic system

m with working oil :
eral hydraulic oil or equivalent, and keep the working oil fully
Apply good grade mine
supplied into the hydra

aulic cylinder, oil tank, and piping system.
Any air in the hydraulicc system will produce abnormal noises from the
e hydraulic pump and
cause not only unstable rudder angle but also other troubles. In case
e of replenishing the
working oil, use the oill of same brand.
(2) Correct operation of sttop valve :
Correctly open and clo

ose the stop valve and isolating valve in accorda
ance with the
instruction plate.
͛ Air vent valve :
Never open the valves during the steering gear is operated. If not, it will cause the
failure of steering.
͛ Safety valve :
ety valve unreasonably because it has been corrrectly adjusted.

Never touch the safe
(3) Lubrication and rust prrevention of each part :
Properly apply the lubrricant on the ram surfaces and sliding levers.
Apply the grease on th

he part where is afraid of rust due to the enviro
onment.
(4) Pump starting :
͛ Start the hydraulic pu

ump in neutral position as far as possible.
Starting up under a big eccentricity will have the possibility of caussing the excessive
current of the electric motor.

UTEK Steering gear
͛ Pay attention especia
ally when the hydraulic pump is started at low ttemperature such as
winter season (below

w 10୅
୅ approx.).
After ensuring the oil temperature

t rises by keeping small eccentricity and steering small
rudder angles, start the normal steering.
(5) Pump stop :
Stop the hydraulic pum

mp after ensuring that the rudder angle is in ne
eutral(zero) position.
(6) Pump operation at zerro tilting angle :
Long-time operation off hydraulic pump at zero tilting angle at anchorr should be avoided as
far as possible.
If unavoidable, it should be limited within 24 hours, because this will be undesirable for the
lubrication between cyylinder and valve plate of the hydraulic pump.
(7) Check items :
Checks shall be carried

d out surely by referring to item 6.2 and 6.3.
Special care should be

e taken to the oil level and temperature of tthe oil tank, operating
conditions of hydraulicc pump and steering gear, tightness of bolts, oill leakage etc.

UTEK Steering gear
6.2 Check items :
Period Che
eck items Period Check items
A-1 Oil quantityy (1) Oil quantity
A-2 Oil tempera

ature (2) Valve positions
A-3 Cylinder pre

essure (3) Oil tem
mperature
A-4 Abnormal noises

n Before (4) Lubriccation of sliding parts
Daily Voyage
A-5 Oil leakage check (5) Ram ssurface
A-6 Current of electric

e motor (6) Pump neutral position
A-7 Servo pump

p pressure (7) Opera
ating condition
A-8 Torque mottor temperature (8) Air release
erating condition
B-1 General ope (1) Safetyy valve
Weekly B-2 Lubrication of sliding parts (2) Rudde

er turning speed
B-3 Cleanlinesss of machined parts (3) Coupliing

(4) Clearaance between tiller
C-1 Ram V-packking
and rooller
(5) Pressuure gauge and
C-2 Air vent vallve
thermo ometer
Monthly
(6) Bolt, n
nut, pin and
C-3 Stop valve and isolating valve
turnbuuckle
C-4 Oil seal of pump
p control unit (7) Ram V
V-packing
al of pump control
(8) Oil sea
D-1 Bolt, nut, pin
p
unit
Periodical
D-2 Turnbuckle
e Checks (9) O-ring
g of pipe joints
(at dock
Quarterly D-3 Coupling Or basin) (10) Gaskket packing
D-4 Oil level sw

witch (11) Cylin
nder bottom packing
D-5 Line filter (12) Pump

p control unit
E-1 Slide plate of ram guide bar (13) Electtric motor

Semi-
yearly
E-2 Working oil-visual check (14) Workking oil
(15) Tankk cleaning

Yearly F-1 General fun
nction and
appearance
(16) Line filter cleaning
F-2 Working oil-property
(17) Hydrraulic pump
inspection
(18) Air re
elease

UTEK Steering gear
6.3 Detail of check item
ms :
6.3.1 Normal checks :
Carry out the follow

wing checks whenever the ship is navigating or anchoring and take
proper measures if necessary.
A) Daily checks :
n oil tank :
A-1 Oil quantity in
͛ Check the oil level in oil tank is within the visible range of th
he oil level gauge. If
e the cause, repair if necessary and refill oil tank with new clean oil.
not, examine
A-2 Oil temperatu

ure in oil tank :
͛ Check the oiil temperature in the oil tank by comparing with

h the normal data.
Normally oill temperature will be within 30୅ plus room tem

mperature. If it
exceeds 80୅, stop the hydraulic pump and examine the ccause.
A-3 Hydraulic cylinder pressure :
͛ Check the prressure of hydraulic cylinder by means of the p

pressure gauge by
comparing with
w the normal data. If it is abnormally high, e
examine the cause.
A-4 Abnormal noises :
͛ Check its oriigin in the steering gear and examine the cause
e.
A-5 Oil leakage :
͛ Check for oill leakage from the oil tank, hydraulic cylinder, vvalves and pipe joints.
A-6 Current of ele

ectric motor :
͛ Check for exxcessive current of the electric motor.
A-7 Servo pump pressure

p
͛ Check the prressure of servo pump by means of the pressure gauge.
Adjusting prressure is 1.8 ~ 2.0 MPa {18 ~ 20 kgf/cm2}.
A-8 Torque motorr temperature
͛ Check the te
emperature of torque motor, by comparing with
h the normal data.
Normally tem
mperature will be within 30୅ plus room temperrature. If it exceeds

UTEK Steering gear
80୅, stop th
he torque motor and examine the cause.
B) Weekly checks :
ating condition of steering gear :

B-1 General opera
͛ Check the stteering gear is in normal operation. Expel air in

n its circuit, if
necessary.
B-2 Lubrication off sliding parts :
͛ Lubricate the
e ram surface, tiller hardened steel plate, rollerr bearing and levers.
Apply the ram

m surface with working oil and apply other surffaces with a light film
of grease.
B-3 Cleanliness off machined parts :
͛ Make periodical cleaning and try to prevent rust by applyin

ng grease.
C) Monthly checks :
C-1 Ram V-packin

ng :
͛ Check a light film of oil is produced on the ram surface.
Adjust the gap

g between packing gland and cylinder, if nece
essary.
C-2 Air vent valve

e:
͛ Check the va
alves are securely closed.
If not, tighten them hard up not to be loosened by vibration

n.
C-3 Isolating valve and stop valve :
͛ Check the va
alves are opened or closed correctly in accorda
ance with the
instruction plate.
p Tighten them hard up by means of lock n
nuts not to be
loosened byy vibration.
C-4 Oil seal of pump control unit :
͛ Check for oill leakage from the drain inspection ports provid
ded at the foot of
torque moto
or. Renew oil seal (Fig.13-109), if necessary.
D) Quarterly checks :
D-1 Bolt, nut and pin :

UTEK Steering gear
͛ Check the fixxing condition of each bolt, nut, pin, pressure g
gauge and valves.
If loosen, tig
ghten them evenly and hard up.
D-2 Turnbuckle :
͛ Check the nuts and lock washers for turnbuckle are tighten
ned hard up.
D-3 Coupling :
* Exchange th
he grease in the chain coupling.
Turn off the power

p of electric motor and steering stand befo
ore starting the work.
First exchang
ge : Within one month
Second excha
ange or more : Every three months
D-4 Oil level switcch :
͛ Confirm thatt the alarm is given by pushing up the test bar of float switch
mounted on
n the oil tank.
D-5 Line filter
͛ Check the clogging condition of filter by means of visual indicator. Wash the filter
element, if necessary
n (Refer to item 6.5).
E) Semi-yearly checkks :
E-1 Slide plate of ram guide Bar (white resin) :
͛ Check for an
ny abnormal wear.
E-2 Working oil-viisual check :
͛ Sample the working

w oil each from the hydraulic cylinder an
nd oil tank. (Inspect it
by visual check and if found abnormal, examine in detail.)
F) Yearly checks :
F-1 General functtion and appearance :
͛ Make a preccision inspection if necessary, and repair or rene

ew defective parts.
͛ Clean thorou
ughly.
F-2 Working oil-prroperty inspection :
͛ Make a perio
odical property inspection of the working oil.

UTEK Steering gear
Sample abou
ut 1.0 lit. of working oil each from the hydraulicc cylinder and the oil
tank. Renew the working oil, if necessary. (Refer to item 6.3

3.4.)
6.3.2 Before voyage checkks :
Check the followings before leaving the port.
(1) Oil quantity in oil tank :
͛ Check the oil levvel in oil tank is within the range of the oil leve
el gauge.
(2) Valve positions :
͛ Check the valve

es are opened or closed correctly in accordance
e with the instruction
plate.
(3) Oil temperature in

n oil tank :
͛ Check the therm

mometer is not damaged.
͛ Check the oil te ୅ to 60୅).

emperature is within proper range. (about 10୅
(4) Lubrication of slid

ding parts :
͛ Check the lubriccating condition of each sliding part. Check for any rust.
(5) Ram surface :
͛ Check for excesssive leakage from the Ram V-packing.
The ram surface will be cleaned thoroughly.
(6) Pump neutral possition :
* Start the hydrau

ulic pump one by one and confirm that ram doe
es not move large by
non-follow up steering
s mode in no-load condition.
* If it moves 0.5 degrees/min.

d or more, adjust by referring to Ittem 4.2.4.
(7) Operating condition :
͛ Check the rudde

er moves correctly by the order signal from the
e wheelhouse (bridge)
and the actual angle agrees with the order angle.
(8) Air release in hyd

draulic system :
͛ Expel air in the hydraulic system.
6.3.3 Periodical checks (att dock or basin) :
While the ship is at dock,

d periodical checks should be carried out where cannot be

UTEK Steering gear
examined fully at norrmal checks. Check in detail where found impro
opriety at normal check
and repair if necessary.
(1) Safety valve :
͛ Check the safetyy valves are set at adjusting pressure. (The adjjusting pressure is
marked with red on the dial plate of the pressure gauge.)
͛ If not set, re-ad

djust it (Refer to item 4.2.10).
͛ When testing, check

c for oil leakage from the seal.
(2) Rudder turning sp

peed :
͛ Examine the rud

dder turning speed at basin trial and confirm th
he rudder can be
moves from 35 degrees

d on either side to 30 degrees on the oth
her side within 28
seconds (except for special requirements).
͛ Check there is no
n large difference between the above data and
d the trial data.
(3) Coupling :
͛ Check the errors of centering are within the standard value byy measuring the
centering of couplings with the dial gauge (Refer to Fig. 20).
If exceeding the standard value, re-adjust it by referring to ite

em 4.1.4.
en tiller and roller bearing :

(4) Clearance betwee
͛ Check the cleara

ance between hardened steel plate and roller b
bearing is within the
permissible valu
ue.
If not, adjust with

w the liner or replace the hardened steel plate
e.
͛ The permissible
e value of clearance : 0.5mm
(5) Pressure gauge and

a thermometer :
͛ Check for norma

ality.
͛ Repair or replacce if necessary.
(6) Bolt, nut, pin and

d turnbuckle :
͛ Check the tightn

ness of all bolts, nuts, turnbuckles and also che
eck for wear of the
pins.

UTEK Steering gear
͛ Tighten addition
nally or repair if necessary.
(7) Ram V-packing :
͛ Replacement off packing is not required when there is no oil leakage from the
packing gland under

u the condition that packing gland can be ttightened and there is
a light film on the

t ram surface.
͛ Even if oil leaka

age is not observed, it is desirable to renew it a
about every five years.
(8) Oil seal of pump control unit (Pump Regulator) :
͛ If oil leakage is observed from the drain inspection ports proviided at the foot of
torque motor, renew oil seal.
age is not observed, it is desirable to renew oil seal about every five
years.
(9) O-ring of pipe joints :
͛ If oil leakage is observed, renew it.

age is not observed, it is desirable to renew it a
about every five years.
͛ If the back-up ring

r is not damaged, it can be further used as itt is.
(10) Gasket packing :
͛ If oil leakage is observed, renew it.
͛ If sufficient thicckness is kept and damage is not observed, the

e packing may be used
as it is by tighte
ening additionally.
(11) Cylinder-bottom
m packing : (Fig. 2)
͛ If oil leakage is observed, tighten the packing additionally.
If oil leakage iss not stopped, tighten it again by touching the rram to the plug and
raising the presssure up to the adjusting pressure of the safetyy valve.
Caution :
This packing hass been installed inside of the hydraulic cylinder. Therefore the packing
cannot be renew
wed unless the ram is drawn out.
(12) Pump control un

nit :

UTEK Steering gear
͛ Check that the stopper
s is adjusted to the position of the max. pump tilting angle
plus 2 ~ 3mm. Refer to Item 4.2.7.
(13) Electric Motor :
͛ Measure insulattion resistance between stator coil and frame (m

more than 10 Mƻ). If
found faulty, re
epair or replace the electric motor.
* It is desirable to
o renew the bearing of the electric motor for se
ervo pump about every
three years.
(14) Working oil :
͛ Sample the oil each

e from the oil tank and the hydraulic cylinde
er and make a property
analysis.
͛ Whenever the oil

o reaches the renewal standard, renew it with new one.
(15) Tank cleaning :
͛ Clean thoroughlly the interior of the oil tank when the working oil is renewed or
about every two

o years.
(16) Line filter cleaning :
͛ Even if the clogging condition is not observed by means of visual indicator, it is
desirable to clean the filter when the working oil is renewed o

or about two years.
(17) Hydraulic pump :
͛ Care should be taken especially to worn-out parts, cylinder, va

alve plate and all
bearings.
͛ For details, refe

er to item 6.6.
(18) Air release :
͛ Expel air after periodical

p checks.
6.3.4 Check of working oill :
As it is used long perriod the working oil will be mixed with foreign m
matters, deteriorated
in the quality, and ha

ave the inconvenience to keep on the normal op
peration of the
steering gear. To avo

oid this, the oil should be subjected to the perio
odical inspection.

UTEK Steering gear
Sample the oil at leasst every half a year for visual check and every year for detailed
property inspection and

a decide its suitability.
If the result exceeds the renewal standard, renew the working oil.
During the visual che

eck (spot judgment), carefully observe the follo
owing points compared
with the new oil :
ned from light yellow to dark brown ?

a. Isn't the color turn
b. Isn't the smell producing an irritative smell ?
n of foreign matter ?
c. Isn't there any sign
d. Isn't it emulsified ?
Working Oil Renewal Standards
Ch hanges resulting from Working limit

Item Cause
detterioration and pollution (changing rate)
Specific gravity Increase Deterioration 0.05

Flash point Decrease Deterioration 60୅
Oxidation, mixture 㧔Union㧕
Color Darken
of worn powder 2
Viscosity Increase (decrease) Deterioration ±10%
Acid value Increase Oxidation 0.4 mg KOH/g
Humidity Increase 0.05 %
6.4 Replacement of ram V-packing

V : (Fig. 23)
During the replacementt work of the packing, care should be taken to avoid damaging the
ram surface and seal su

urface of the cylinder.
Five packings are insertted in each hydraulic cylinder. To facilitate the w

work, oblique cut has
previously been made in one portion.
(1) Drawing out of packking :
V-packings can be drrawn out by making use of the friction with the ram.
a. Loosen the nut and

a lock nut of the packing gland by about 2m
mm.
b. Move the ram slowly by local steering. (The packing can be drrawn out little by little
along with the ram.)

UTEK Steering gear
c. The packing can
n be drawn out by repeating above works a and
d b.
If packing canno
ot be drawn out by above work, prepare a suita
able tool and draw out
the adapter and packing. (The screw holes has been machined
d on the female
adapter for disasssembling.)
(2) Inserting of packing

g:
a. Before inserting new

n packings, thoroughly remove dirt and impu
urities stuck on the
interior of the stuffing box and the ram surface.
b. Insert the male adapter

a inward.
c. Wind the new paccking to the ram. At the moment, confirm that the section is
correctly met. (If the packing is hard, make it soft by hand rub
bbing.)
g inward by fingers or a bamboo spatula to sup

d. Insert the packing pport the packing.
e. Follow the same manner subsequent to the second one. At the moment, the
splits in the packking should be staggered around so that no two

o splits come
together.
f. Insert the female adapter and tighten the packing gland.
aken then not to allow one-side tightening. The

Care should be ta e suitable clearance
between the cylin

nder and the packing gland is shown in Fig. 23.
g. Operate the steerring gear by the pump control knob and adjustt the packing gland
to form a light film of oil on the ram surface.
h. Check for excessiive oil leakage by raising the pressure up to the

e adjusting
pressure of safetty valve.
Cautions :
1. Assembly of wrrong inserting direction of ram V-packing will le

ead to failure in
sealing.
e taken to the packing since it tends to turn up itself when inserting.

2. Care should be
3. New packing may

m occasionally cause oil leakage in the first co
ondition.
Tighten them additionally

a if necessary.

UTEK Steering gear
6.5 Dismantling and assembling of line filter : (Fig. 19)
When the indicator (8) of the filter shows the clogging condition (red ind
dicator ring is floated
up to the white level in the column), the line filter will be dismantled and
d the filter element (5)
is changed to new one or cleaned in the following procedures. It will be desirable to clean
when the ring reaches the

e middle position in height.
a) Stop the electric motor..
b) Loosen slightly the U-bolt and nuts for filter support.
c) Grab the hexagon plug on bottom of filter case (2) with large monkeyy spanner (about 300
mm), turn the left dire

ection in order to loosen the filter case (2).
Caution :
During the removal of

o filter case (2), care should be taken not to sspill the remaining oil
inside of filter case.
er case (2), hold the filter case and filter element respectively with
d) After loosening the filte
hands, and pull out the filter element downward with twisting slightly.
e) Wash the filter elementt (5) by shaking in the washing oil and clean itss surface by using a
soft cloth. It is desirable

e to blow from the outlet side with compressed
d air.
If filter element is dama

aged, renew the filter element.
f) Discharge the oil in filte

er case and clean the interior of filter case.
g) The assembly of the filtter will be performed in reverse order to that o

of disassembly.
Caution :
1) Check the o-ring (3) & back-up ring (4) before assembly, which are inserted inside
of filter head (1), for prevention of oil leak between filter case(2)) & filter head(1).
2) Tightening torque
e of filter case (2) : 160 Nȡm (16 kgȡP
6.6 Dismantling and assembling of hydraulic pump : (Fig. 8 & 10)
The hydraulic pump willl be dismantled and checked in the following prrocedures.
However, special attentiion and skill in dismantling and assembling of tthe pump are required,
so it is recommendable that the work is performed by the specialist, iff possible (Exploded
view of axial piston pum

mp in Fig. 8 & 10 is referred to).

UTEK Steering gear
(1) Preparatory items :
a. Tools necessary fo
or dismantling and assembling of the pump (ba
ar spanner M4 ~ M20,
pliers, driver, ham

mmer, monkey wrench, depth gauge)
b. Clean waste cloths and wooden pieces for bed seat
c. Washing oil (abou

ut 10 liters)
d. Chain block, 2 setts (0.5 ~ 1 ton capacity)
e. Spare parts of pum

mp
(2) Procedures for Disasssembly :
a. Discharge oil conttained in the oil tank, disconnect the hydraulic regulator, hydraulic
pipe, each valve, electric

e motor and the pump coupling, remove the pump from the oil
tank and lift the pump by the chain block. Place the pump on a proper wooden piece.
Caution :
Disassemble at a clean
c place.
b. Remove the valve

e cover (253) from the cylinder casing (202).
Caution :
The copper packin

ng (203) is used at the ports of valve cover.
Replace the coppe

er packing at assembly.
c. Remove the suctio

on valve cover (280) and the poppet (281).
d. Remove the valve

e plate (171) from the valve cover (253).
e. Pull out the cylind

der (151) and the center rod (161).
Caution :
1) Care should be taken not to lose the cylinder spring (165) beccause it is come out
together with cylinder.

c
2) Place the cylind

der taking care not to damage the sliding surfacce (spherical part).
f. Remove the both pipe

p flanges (254).
Caution :
Shims (211) for adjustment

a (centering) of the cylinder casing (2
202) are inserted
together with the

e thrust pad (210). Keep the top and the bottom
m shims separately to
prevent mistakess in assembly.

UTEK Steering gear
g. Remove the both supporting axle (208) from the cylinder casing
g (202).
h. Remove the cylind

der casing (202) from the bearing casing (201)).
Caution :
Remove the cylind

der casing by means of the chain block since th
he weight of casing is
larger according to
o the size of pump.
i. Remove the key (1

102) and then the front cover (251).
Caution :
1) Remove the covver by using the drawing bolt holes without gra
aver and driver.
2) Remove the fro

ont cover taking care not to damage the lip of tthe oil seal (103). If it
is damaged, re
eplace at assembly.
j. Remove the stop ring

r (105), the inner shim 2 (106) and the inne
er spacer (109) from
the driving shaft (101).

( They will come out by striking the top off the shaft with a
wooden hammer (Remove

( the stop ring by using a pliers).
k. Grip the piston su

ub (01) and pull out the driving shaft.
Caution :
1) Check that therre is nothing wrong with the roller bearing (104
4) and the tapered
111). If nothing, don't pull out them and leave inside of the bearing
roller bearing (1
casing (201).
2) Don't remove the piston, connecting rod etc. from the driving shaft (101).
l. With the above, th

he disassembly is finished.
(3) Check and repairs :
After the disassemblly is finished, check and repair each part.
Ꮿ Worn componentts :
Care should be ta
aken especially to the wears between the pisto
on sub and the cylinder,
the piston and th

he small spherical end of connecting rod, the la
arge spherical end of
connecting rod and the set ring, the center rod and the cylinderr. If there is no
abnormal increasse in the clearance and remarkable visual dama

age, replacement of
them will be unnecessary.

UTEK Steering gear
Standards for Replacement of Worn Parts (Unit: mm)
Pump siize
030 060 090 120 180 260 500
Item
Nominal size 16 20 22 25 28 32 40
Standard
Piston and 0.024 0.030 0.033 0.037 0.042 0.048 0.060
clearance
Cylinder Recommended
Replacement 0.050 0.060 0.070 0.080 0.090 0.100 0.120
Clearance
Standard
0.15 0.15 0.15 0.15 0.20 0.20 0.25
clearance
Piston and
Recommended
Con-rod Replacement 0.50 0.50 0.50 0.50 0.55 0.55 0.60
Clearance
Standard
Con-rod 0.09 0.09 0.10 0.11 0.14 0.17 0.19
clearance
and Recommended
Set ring Replacement 0.20 0.20 0.20 0.25 0.30 0.35 0.40
Clearance
Nominal size 16 20 22 25 28 32 40
Center rod Standard
0.024 0.030 0.033 0.037 0.042 0.048 0.060
and clearance
Cylinder Recommended
Replacement 0.050 0.060 0.070 0.080 0.090 0.100 0.120
Clearance
Ᏸ Cylinder and valve plate

e:
If the sliding surfaces off the cylinder and the valve plate are roughene
ed, replace them at the
same time. And if the worn
w value of the valve plate is over although slliding surfaces are in
normal condition, replacce the cylinder and the valve plate at the same
e time.
The correction standards are as follows :
Parts Item Standards ffor Correction
Cylinder Surface roughness requiring 3.2-a Note 1)
Valve plate correction 㧔approx.ୠୠfiinish㧕

Recom
mmended replacement
Hs 84
hardn
ness
Valve plate
Working limit (replacement) Hs 82 and und
der
Stand
dard hardness Hs 90 and ove
er
Note 1) 3.2-a indicates a sttate of roughened sliding surface which makes yo

ou feel a considerable
scratching when you
y apply your nail to the sliding surface.
Ᏹ Bearing :
eling off on the surface of the bearing.

Check for flaws and pee
Caution :

UTEK Steering gear
When replacing the rolle
er bearing, the tapered roller bearing and the n
needle roller bearing,
consult with us for essential information.
(4) Procedures for assem

mbly :
The assembly of the

e pump will be performed in reverse order to th
hat of disassembly.
However special atte

ention should be paid on the followings :
Ꮿ General cautions :
a. Repair the parts if damaged at disassembly work. Prepare the p

packings before
assembly.
b. Wash each part thoroughly

t with the washing oil and dry it by b
blowing with
compressed air. Use

U of waste cloth shall be avoided.
If waste cloth is used, take care that fiber scraps will never rem
main on the cleaned
parts.
c. Apply clean workking oil on the moving parts before assembly.
d. Tighten the boltss in symmetrical order little by little by referring

g the table.
Tightening Torque
Bolt size
Material Item Unit
M4 M5 M6 M8 M10 M12 M16 M18 M20
kgf·cm
m 35 70 120 300 580 1,000 2,400 3,400 4,400
SCM435 Torque
N·m 3.4 6.9 11.8 29.4 56.9 97.1 235.4 333. 431.5
Ᏸ Cautionary Instructio
ons in Assembly :
a. When installing the

e oil seal (103)
to the front cover (251), carry out
the hammering-in after applying
g to the periphery
the liquid packing
of the oil seal.
Fill the grease intto the oil seal lip
space and carefu

ully install the front
cover to the bearring casing (201).

UTEK Steering gear
b. When inserting the
e O-ring (260) and
back-up ring (26

61 and 263) into
the pipe flange (254),

( care should
be taken in the direction

d of them.
c. When inserting th
he thrust pad
(210) and the shim (211), care
should be taken not to be wrongly
inserted.
As the thrust pad and the shim
may be fallen, prevent

p falling by
applying the gre

ease etc.
d. When installing the

t valve plate (171) to the valve cover (253), apply the grease
etc. for preventing falling of the valve plate.
e. When installing the

t copper packing to the port of the valve covver (253), replace it
for new one.
As the packing may

m be fallen at assembly, prevent falling from tthe port by applying
the grease etc.
f. After the assembly is over, rotate the driving shaft (101) by han
nd and ensure there
is no abnormalityy.
Then, install the pump inside of the oil tank and put it to the orriginal condition.
6.7 Dismantling proce

edures for pintle bearing inspection :
When inspecting the pintle

e, the rudder plate must be jacked up 400 to 5
500mm.
ne as it is because the arms of fork-typed tiller have inserted the ram

However, it cannot be don
at upper and lower parts.
Therefore, dismantle the steering

s gear in the following procedures by refferring to Fig. 1 & 24 :

UTEK Steering gear
a. Remove all connecting
g levers above the tiller.
b. Remove the stop ring for ram pin with a pliers and take off the upper and lower roller
bearings.
Caution :
The lower roller beariing will drop if the stop ring is removed, so safe
ety is especially given
to the work.
c. Loosen the bolt and re

emove the guide bracket.
d. Loosen the ram pin se

et screw by around 20mm.
e. Jack up the ram pin from the lower part and pull out it completely up
pwards.
f. Carefully and slowly turn the tiller and rudder plate (rudder stock) by means of a winch at
the dock up to the 90 degrees position as shown in Fig. 24.
Caution :
For the rudder plate not

n allowing the 90degrees turn due to the hull construction, remove
the key, jack up only the tiller and turn it up to the 90degrees positiion.
g. Jack up the rudder pla

ate (rudder stock) and the tiller in such conditio
on, and inspect the
pintle portion.
h. After the inspection, assemble

a the steering gear in reverse order to tthat of disassembly.
At the moment, screw the set screw for ram pin and bolts for guide b
bracket without fail.

UTEK Steering gear
7. Trouble shootin
ng guide
Flutek-Kawasaki Type Electro

o-Hydraulic Steering Gear has sufficient strength and durability. In the
event of trouble, it is necessa

ary to let us know exactly what has been obserrved and what
measures have already been taken.
7.1 General notes :
(1) The Steering Gear Sysstem is considered to be classified into the auto
o-pilot system
(including the repeat back

b unit and gyro compass) that outputs the rudder order angle
in the wheel-house (brridge), the continuous control system such as tthe control box,
the pump control unit etc, that controls the pump tilting angle in the steering gear room
with the above order received, and the steering gear, such as the ram
m, the cylinders,
the tiller etc.
Any poor rudder respo

onse from the wheel-house (bridge) should be a
always dealt with by
separating the auto-pillot system and the continuous control system ffrom the steering gear
for earlier discovery off the cause.
en for failure in any power unit, stop the power unit concerned (and
(2) When an alarm is give
then start another pow

wer unit). Then, investigate the defective part.
e cause of the trouble, operate the steering gear by the pump

(3) When investigating the
control knob in the ste

eering gear room (i.e. local steering). If the trou
uble continues,
the cause will be in the

e steering gear and the detailed check of the stteering gear should
be carried out.
perates in order, the cause will be in the auto-pilot system or the

If the steering gear op
continuous control systtem. Then proper remedies should be taken byy referring to the
Instruction Manuals off their systems.
e entry of dirt and

(4) When carrying out investigation and remedy, take care to prevent the
dust, and handle the parts

p not to damage them.
(5) Take smooth procedurres in the transportation and disassembly of heavy weights, and
pay attention to safetyy.
(6) If the cause is not clea

ared ask our company.

UTEK Steering gear
7.2 Trouble shooting of
o steering gear :
Investigate the cause an

nd take measures by referring to Fig. 25 Troub
ble Shooting Flow
Chart.
(1) Steering Gear does not work :
e:
a. External oil leakage
͛ Check for oil leakkage from the ram V-packing and connections.
Tighten them add

ditionally or replace the packing if necessary.
b. Electric motor doess not rotate :
͛ Check that the sttarter is in normal operation.
͛ Disconnect the co
oupling with the hydraulic pump and investigate
e which is in trouble,
the motor or the hydraulic pump.
c. Trouble or mis-operation of valves :
͛ Check that the sttop valve and isolating valve are opened or clossed as indicated on
the instruction pllate.
d. Investigate any obstacles around the tiller and ram.
ety valve is surely set.

e. Check that the safe
f. Check that the air vent

v valve is closed.
g. Poor tilting of hydraulic pump :
ervo pump pressure is 1.8 ~ 2.0 MPa {18 ~ 20kkgf/cm2}.

͛ Check that the se
͛ Check for abnorm

malities of the torque motor of the pump contro
ol unit.
͛ Check for normal operation of LVDT of the pump control unit (p

pump regulator).
h. OB valve does not change over to on-load condition :
͛ Check for correctt change-over of the solenoid control valve for u

unloading device and
check that the electric source is supplied.
g of the solenoid and for sticking of the spool.

͛ Check for burning
If the spool sticks, remove it for lapping.
i. Trouble of Hydraulicc Pump :
͛ Check for abnormal noise of running pump or the opening of the suction valve.
ems to be found abnormal, disassemble and ch

If the pump see heck the pump and
make necessaryy remedies. (Refer to item 6.6)

UTEK Steering gear
(2) Rudder turning speed is slow :
The time of rudder turrning speed is measured when the rudder move
es from 35 degrees on
either side to 30 degre

ees on the way to 35 degrees on the other side
e (excluding special
requirements).
a. External oil leakage :
e from the ram packing and connections.

Check for oil leakage
Tighten additionally or replace the packing if necessary.
b. Trouble or mis-operattion of valves :
Check that the stop valve and isolating valve are opened or closed as indicated on the
instruction plate.
c. Investigate any obsta

acles around the tiller and ram.
d. Poor setting of safetyy valve :
Check that the adjussting pressure of the safety valve is not reduced
d.
e. Check that the air vent valve is closed.
f. The maximum tilting angle

a of the hydraulic pump is small :
Check the specified maximum tilting angle of the hydraulic pump.
If excessively small, re-adjust it with the control box.
g. OB valve does not ch

hange over to on-load condition :
Refer to item 7.2 (1)) h.
h. Trouble of hydraulic pump

p :
Refer to item 7.2 (1)) i.
(3) Steering Gear does no

ot work smoothly :
a. Air contained in hydra

aulic circuit :
Air contained in the hydraulic circuits will cause the delayed respon
nse.
Expel air periodicallyy without fail. (Refer to item 4.2.5)
b. Investigate any obsta

acles around the tiller and ram.
c. Over-tightening of ram V-packing :
e has roughly been set up depending upon the type of steering gears.
The tightening value
Over-tightening will cause oil shortage or intermittent movement o

of the ram.
(Refer to item 6.4)
d. The tilting angle of th

he hydraulic pump is changed :

UTEK Steering gear
Refer to item 7.2 (1)) g.
e. Play between rudder stock and bearing :
pair it while the ship is at dock. (Consult with th

Disassemble and rep he shipyard.)
(4) Steering gear is unstab

ble (Steering gear does not stand still) :
a. Poor neutral adjustment of hydraulic pump :
on of the hydraulic pump shifts when the pump

If the neutral positio p tilting angle order
is zero, the steering gear will not stand still.
Adjust the pump neu

utral position as shown in item 4.2.4 and the ze
ero adjustment of the
control box as shown in item 4.2.6.
Don’t leave it in non-follow up control for a long time because rudd

der may be
moved slowly by extternal force as non-follow up steering mode is n

not fed back the
actual rudder angle.
b. Poor setting of propo

ortional band :
If the proportional band

b is adjusted too small in the control box, th
he steering gear will
not stand still. Re-ad

djust the proportional band to 2degrees ~ 5deg
grees.
c. Excessive clearance of
o the pin of pump control unit :
If the clearance of th
he pin of pump control unit becomes abnormallly great,
following-up to the order

o from the control box becomes unstable and the steering gear
will not stand still.
Repair it or replace its part if necessary.
d. Excessive clearances of pin for repeat back unit :
he pin for repeat back unit becomes abnormallyy great, actual rudder
If the clearance of th
angle signal to the steering

s stand becomes unstable and the steeriing gear will not stand
still. Repair it or repllace its part if necessary.
e. Excessive clearance between

b tiller arm and roller bearing : (Fig. 1)
If the clearance betw

ween the hardened steel plate (1003) and the rroller bearing (1121)
becomes abnormallyy great, the steering gear will not stand still.
(Refer to item 6.3.3 (5)).
f. Poor shut of air vent valve

v :
Repair the sliding pa

arts so that the valve can be surely closed.
g. Poor adjustment of control box :

UTEK Steering gear
Re-adjust it by referring to the instruction manual of the auto-pilott manufacturer.
e ship is under voyage :

(5) Abnormal Noises while
Abnormal noises can be

b dealt with by full confirmation of their originss.
a. Occurring wheneverr the rudder is worked :
Expel the air thorou

ughly because a great amount of air remains in
n the hydraulic
circuits.
Check further for exxistence of place to allow air to enter. (Refer to

o item 4.2.5.)
b. Noises from ram V-p

packing :
This is caused by excessive

e tightening of the ram packing (Refer tto item 6.4).
c. Noises from rudder carrier :
Ask the shipbuilderr concerned. Check the lubricating condition tho

oroughly.
d. Abnormal noises fro

om pump :
Immediately stop the operation for detailed check. Disassemble o

or repair the pump,
if necessary.
e in all cylinders :
(6) Abnormal pressure rise
Confirm that the valve

e is operated in accordance with the instruction
ns.
(7) Rudder moves while ship is at anchor :
or for long time, the rudder may move owing to

If the ship is at ancho o the influence of the
air in the cylinder and

d the oil leakage from valves. If this causes vibrration of the hull, start
the pump and fully exxpel the air. (Operate the steering gear at leastt every 24 hours.)
When the stop valvess are provided on the hydraulic cylinders, closin
ng of the valve will be
effective. In this case

e, don't fail to open the stop valve before startin
ng the pump.
7.3 Trouble Shooting of

o valve, pump and electric motor :
When the pump is found in

i failure and required disassembly for check, d
do it after full
understanding of item 6.6

6.
(1) Stand-by pump rotatess in reverse :

UTEK Steering gear
͛ If the stand-by pump
p rotates in reverse at high speed, it will cause steering failure. To
prevent it, the oil blo

ock valve is provided.
It is therefore necessary to disassemble the OB valve for detailed ccheck. Special care
should be taken to check

c that the spool is not sticky, damaged, abn
normally worn out,
the check valve is no

ormal, or the casing is not damaged, deformed
d, etc. After the
check, take necessary measures, such as lapping the spool, facing up the seat of the
check valve, etc. If the

t reverse rotation influences upon the rudderr turning speed in
spite of the above re

emedies, replace the OB valve.
In this case, ask ourr company immediately.
͛ For an emergency measure,

m it can be prevented by simultaneous o
operation of two
pumps.
(2) Excessive temperature

e on pump bearing casing :
͛ The bearing casing temperature will become higher by 10 to 20୅

୅ tthan the oil
temperature. If this difference is abnormally large, stop the pump iimmediately for check.
a. Poor centering betw

ween pump and electric motor :
Re-adjust the centerring by referring to item 4.1.4.
Investigate the causse of such poor centering.
b. Dust biting in bearin

ng :
͛ Check that it is nott abnormal by rotating the pump by hand.
c. Oil shortage in oil se

eal :
Oil shortage will cau

use high temperature in the oil seal.
Apply sufficient amo

ount of grease.
(3) Excessive oil temperatture in oil tank :
Depending upon the ro

oom temperature, while the pump is running th
he pump will be set
approximately at the ro
oom temperature plus 30୅.
If the oil temperature rises

r above 80୅, stop the pump to investigate
e the cause.
a. Disassembling checkk of pump :
Refer to item 6.6.
b. Check of working oil :

UTEK Steering gear
Refer to item 6.3.4.
(4) Abnormal noise from pump

p :
a. Large amount of airr in hydraulic system :
In this case, cavitatio

on will generate and the rudder will not work ssmooth.
Expel the air thoroug

ghly.
b. Poor condition inside

e pump :
Noise will be caused

d by the breakage of the piston, connecting rod
d or the abnormal
condition of the bearing. Disassemble the pump for check and repa
air.
Foreign matters in th
he working oil may cause troubles, although it is not so often the
case.
(5) Decrease of oil in oil ta

ank in a short time :
͛ Since the hydraulic system

s of the steering gear comprises the close
ed circuit, large
amount of oil decreasse cannot be considered so far as no external o

oil leakage occurs. If
such phenomenon is observed, immediately take proper measures.
(6) Electric motor can not start :
͛ In this case, burning of the electric motor, failure of the electric sou
urce and starter, and
damage of pump can be considered.
Ensure that the coup

pling can be rotated by hand and take proper m
measures.
(7) Abnormal wear of coupling :
͛ Poor centering betwe

een pump and electric motor will cause the abn
normal wear
(Refer to item 4.1.4..)

UTEK Steering gear
*/4536$5*0/4 ."/6"-
FIG.1 ASSEMBLY OF TILLER & RAM
COPYRIGHT FLUTEK, LTD

*/4536$5*0/4 ."/6"-
FIG.2 HYDRAULIC CYLINDER

*/4536$5*0/4 ."/6"-
FIG.3 OIL TANK UNIT
POWER LOCK (1741)

Tightening troque :
178 N.m ± 5%

*/4536$5*0/4 ."/6"-
FIG.4 VALVE UNIT (RE SERIES)
SOCKET BOLT
(2911)
RELIEF VALVE SOLENOID VALVE

(2950) (2904)
OIL BLOCK VALVE (2901)
SHEET PACKING
MANIFOLD (2909)
(2907)

*/4536$5*0/4 ."/6"-
FIG.4 VALVE UNIT (FE SERIES)
EMERGENCY
NORMAL
SOCKET BOLT
(2911)
SOLENOID VALVE RELIEF VALVE
(2904) (2950)
MANUAL CONTROL VALVE

(2902)
OIL BLOCK VALVE (2901)

MANIFOLD SHEET PACKING
(2907) (2909)

*/4536$5*0/4 ."/6"-
FIG.5 FUNCTION OF OB VALVE
RAM HYD. CYLINDER
TILLER
RUDDER STOCK
IDLING PUMP RUNNING PUMP

*/4536$5*0/4 ."/6"-
FIG.6 OB VALVE (OB15)

B CAP SCREW (3-10)
LOCK NUT
SAFETY VALVE
SOCKET BOKLT (171) (3-6) ADJUSTING SCREW (3-2)
T
ADJUSTING PLUG
AC BC (3-1) COPPER PACKING (3-26)
O-RING SPRING SEAT (3-3)
(3-8)
AV BV C-RING (3-4)
A Y X A SPRING (4) NAME PLATE (TYPE) (992)
STICHING RING (6)
CASING (1)
SEAT (541)
NAME PLATE BACK-UP RING (8)
POPPET (511) (SAFETY VALVE) O-RING (7)
(991)
SPRING SEAT (2-3)
UP
SPRING (521)
POPPET (2-2)
SPRING SEAT (531) BUSHING (2-1)
O-RING (561)
B
RO PLUG (551)
BC T
(AC)
SOCKET BOLT O-RING (163)
(171)
SECTION B-B
COVER (201) SAFETY VALVE (600)

O-RING SOCKET BOLT (271)
(162) CASING (101) AC T BC
SEAT (541)
POPPET (511)
SPRING (521)
Y X
AV BV
O-RING
(164) O-RING
SPRING
(161) O-RING (561) HYDRAULIC CIRCUIT
(321)
SPOOL (301)
SPRING SEAT
(331) RO PLUG (551)
SECTION A-A

*/4536$5*0/4 ."/6"-
T
SAFETY VA
COVER (201) SEAT (541)

AC BC
SOCKET BOLT (271) POPPET (511)
C
SPRING (521)
C
SPRING SEAT (531)
Y X
O-RING (561)
AV BV
RO PLUG (551)
SECTION C-C
PLUG (351)
O-RING (162)
SPRING (321) SPRING (322)
SPOOL (301)
WASHER
CASING (101) (331) POPPET
(311)
SECTION A-A
LOCK NUT (3-6)
CAP SCREW (3-10)
ADJUSTING PLUG AC T BC
(3-1) ADJUSTING SCREW (3-2)
SAFETY VALVE
B (600) O-RING (3-8) COPPER PACKING (3-26)
RD20C-10-2/୔
SPRING SEAT (3-3)
Tightening torque
167N.m (1700kgf·cm) C-RING (3-4)
O-RING (3-5) NAME PLATE
SPRING (4) (SAFETY VALVE) (992) Y X
STICHING RING (6) AV BV
CASING (1)
NAME PLATE (TYPE) HYDRAULIC CIRCUIT
(991) BACK-UP RING (8)
UP
O-RING (7)
A A SPRING SEAT (2-3)
POPPET (2-2) Tightening Torque
BUSHING (2-1)
NO. SIZE TIGHTENING TORQUE
171 M16 235 N.m (2400 kgf·cm)
Y AV BV X BC T 271 M12 69 N.m (700 kgf·cm)
(AC) 551 M27 176 N.m (1800 kgf·cm)
B O-RING (163) 600 - 294 N.m (3000 kgf·cm)
SOCKET BOLT SOCKET BOLT
O-RING O-RING (171) (172)
(161) (164)
SECTION B-B ୔ : Setting pressure of relief valve

*/4536$5*0/4 ."/6"-
T
SAFETY VA
COVER (201) SEAT (541)

AC BC
SOCKET BOLT (271) POPPET (511)
C
SPRING (521)
C
SPRING SEAT (531)
Y X
O-RING (561)
AV BV
RO PLUG (551)
SECTION C-C
PLUG (351)
O-RING (162)
SPRING (321) SPRING (322)
SPOOL (301)
WASHER
CASING (101) (331) POPPET
(311)
SECTION A-A
LOCK NUT (3-6)
CAP SCREW (3-10)
ADJUSTING PLUG AC T BC
(3-1) ADJUSTING SCREW (3-2)
SAFETY VALVE
B (600) O-RING (3-8) COPPER PACKING (3-26)
RD30C-10-2/୔
SPRING SEAT (3-3)
Tightening torque
196N.m (2000kgf·cm) C-RING (3-4)
O-RING (3-5) NAME PLATE
SPRING (4) (SAFETY VALVE) (992) Y X
STICHING RING (6) AV BV
CASING (1)
NAME PLATE (TYPE) HYDRAULIC CIRCUIT
(991) BACK-UP RING (8)
UP
O-RING (7)
A A SPRING SEAT (2-3)
POPPET (2-2) Tightening Torque
BUSHING (2-1)
NO. SIZE TIGHTENING TORQUE
171 M16 235 N.m (2400 kgf·cm)
Y AV BV X BC T 271 M12 69 N.m (700 kgf·cm)
(AC) 551 M27 176 N.m (1800 kgf·cm)
B SOCKET BOLT O-RING (163) 600 - 294 N.m (3000 kgf·cm)
O-RING O-RING (171)
(161) (164)
SECTION B-B ୔ : Setting pressure of relief valve

*/4536$5*0/4 ."/6"-
FIG.7 SOLENOID VALVE AND MANUAL ISOLATING VALVE
SPOOL (23)
* THIS DRAWING SHOW EMERGENCY POSITION.
P T
A B
"N" "E"

INSTRUCTIONS MANUAL
FIG.8 AXIAL PISTON PUMP
DRIVE SHAFT
CASING

*/4536$5*0/4 ."/6"-
FIG.9 PRINCIPLE OF PUMP WORKING
A PORT
TILTING PIN LEFT
TILTING
DIRECTION
RIGHT
B PORT
NEUTRAL
a DELIVERY PORT
TILTED
b SUCTION PORT
TILTING DIRECTION RIGHT LEFT
DELIVERY PORT A B
SUCTION PORT B A

*/4536$5*0/4 ."/6"-
FIG.10 EXPLODED VIEW OF AXIAL PISTON PUMP

*/4536$5*0/4 ."/6"-
FIG.11 STEERING SYSTEM BLOCK DIAGRAM
ACTUAL RUDDER ANGLE

STEERING STAND
NO.2 SYSTEM NO.1 SYSTEM SOURCE AC100V-60Hz
RUDDER DEVIATION
AC100V-60Hz
CONTROL BOX CONTROL BOX
MOTOR STARTING AC440V

SIGNAL
TORQUE DIFFERENTIAL DIFFERENTIAL TORQUE
MOTOR TRANSFORMAL TRANSFORMAL MOTOR
AC100V-60Hz
NO.2 MAIN UNLOADING UNLOADING NO.1 MAIN
NO.2 SOURCE NO.1 SOURCE
PUMP DEVICE DEVICE PUMP
NO.2 SERVO NO.1 SERVO

PUMP PUMP
NO.2 MOTOR NO.1 MOTOR
NO.2 MOTOR STARTER NO.2 MAIN MOTOR NO.1 MAIN MOTOR NO.1 MOTOR STARTER
TRANSFORMER TRANSFORMER
RUDDER REPEAT BACK UNIT RUDDER REPEAT BACK UNIT
RUDDER ANGLE LIMITER RUDDER ANGLE LIMITER
: SUPPLIED BY SHIPBUILDER : SUPPLIED BY PILOT MAKER : SUPPLIED BY STEERING GEAR MAKER

*/4536$5*0/4 ."/6"-
FIG.12 PUMP CONTROL SYSTEM

*/4536$5*0/4 ."/6"-
FIG.13 PUMP CONTROL UNIT
TYPE L
REG090 54
REG260 71
REG500 89

*/4536$5*0/4 ."/6"-
FIG.14 CONNECTING DIAGRAM OF PUMP CNTROL UNIT
CABLE COLOR
B : BLACK
BU : BLUE
G : GREEN
R : RED
W : WHITE
Y : YELLOW

*/4536$5*0/4 ."/6"-
FIG.15 TORQUE MOTOR
SOCKET BOLT(4)
STOPPER
LEVER (3)
BOX TYPE
RECEPTACLE (6)
HEX. BOLT (7)
TORQUE MOTOR
REGULATOR
KNOB
OIL TANK

*/4536$5*0/4 ."/6"-
FIG.16 DIFFERENTIAL TRANSFORMER
METAL CONNECTOR (8)
CONNECTOR LOCK (4)
O-RING (13)
SEAL WASHER(6)
END CAP (3)

SPINDLE (11)
COLLAR (5) COLLAR (5)

CORE (10) CASE (2)
FLANGE (1)
COIL (9)

*/4536$5*0/4 ."/6"-
FIG.17 SERVO PUMP UNIT (0.4kW - 3.0cc / REV)
MALE CONNECTOR (2629)
COPPER PACKING (2630)

BRACKET (2604) COPPER PACKING (2607)
HEX. BOLT (2619)
SPRING WASHER (2620)
HEX. BOLT (2623)
ELEC. MOTOR (2601) SPRING WASHER (2625)
TIGHTENING TORQUE
M8 : 300±45kgf-cm
EYE BOLT (2628)
f12 PIPE (2608)
Outlet Inlet
OU T
IN
O-SEAL MALE ELBOW (2605)
GEAR PUMP (2602)
SHEET PACKING (2614)

SOCKET BOLT (2621)
TIGHTENING TORQUE SHEET PACKING (2613)
M8 : 300±45kgf-cm
FRONT COVER (5) GEAR HOUSING (3)

COUPLING (2603)
GEAR SHAFT (4)
LIP SEAL (6) DOWEL PIN (2)
SPACE RING (2618) SNAP RING (7)

SPACE RING (2617)
KEY (8)
COVER (1)
ELECTRIC MOTOR SHAFT PUMP SHAFT SERVO
MOTOR PUMP
BUSH BLOCK (12)
DRY BEARING (11)

SOCKET BOLT (15)
O-RING(9)
CHANNEL SEAL (10) PLANE WASHER (14)
DRIVEN GEAR (13)
SECTION "V-V" GEAR PUMP ASS'Y SECTION

*/4536$5*0/4 ."/6"-
FIG.17 SERVO PUMP UNIT (0.75/1.5kW – 6.5cc/12.0cc- REV)

COPPER PACKING (2630)

BRACKET (2604) COPPER PACKING (2607)
HEX. BOLT (2619)
SPRING WASHER (2620)
HEX. BOLT (2623)
ELEC. MOTOR (2601) SPRING WASHER (2625)
TIGHTENING TORQUE
M10 : 580±85kgf-cm
EYE BOLT (2628)
?12 PIPE (2608)
Outlet Inlet
OUT
IN
O-SEAL MALE ELBOW (2605)
GEAR PUMP (2602)
SHEET PACKING (2614)

SOCKET BOLT (2621)
TIGHTENING TORQUE SHEET PACKING (2613)
M10 : 580±85kgf-cm
FRONT COVER (5) GEAR HOUSING (3)

COUPLING (2603)
GEAR SHAFT (4)
LIP SEAL (6) DOWEL PIN (2)
SPACE RING (2618) SNAP RING (7)

SPACE RING (2617)
KEY (8)
COVER (1)
ELECTRIC MOTOR SHAFT PUMP SHAFT SERVO
MOTOR PUMP
BUSH BLOCK (12)
DRY BEARING (11)

SOCKET BOLT (15)
O-RING (9)
CHANNEL SEAL (10) PLANE WASHER (14)
DRIVEN GEAR (13)
SECTION "V-V" GEAR PUMP ASS'Y SECTION

*/4536$5*0/4 ."/6"-
FIG.18. RELIEF VALVE FOR SEVO PUMP

*/4536$5*0/4 ."/6"-
FIG.20 CENTERING OF HYDRAULIC PUMP AND ELECTRIC MOTOR

*/4536$5*0/4 ."/6"-
FIG.21 AIR RELEASING METHOD

"A"
AIR
RELEASE PIPE
OIL TANK
AIR VENT VALVE
OPEN CLOSE
AIR VENT VALVE
TO OIL TANK
FILLING PLUG
HIGH PRESSURE
RAM
DETAIL "A"
Caution
- Open the air vent valve attached on the cylinder where the ram is drawn
(high pressure. Side) and release the air.

*/4536$5*0/4 ."/6"-
FIG.22 ADJUSTING PROCEDURE OF SAFETY VALVE

*/4536$5*0/4 ."/6"-
FIG.23 ASSEMBLY OF RAM V PACKING
RAM DIA. Ɏ' H (mm)

170~250 2~6
265~425 4~8

*/4536$5*0/4 ."/6"-
FIG.24 DISMANTLING PROCEDURE FOR PINTLE BEARING INSPECTION
ELEC. MOTOR
OIL TANK
GUIDE BAR

*/4536$5*0/4 ."/6"-
FIG.25 TROBLE SHOOTING FLOW CHART (STEERING GEAR)
Steering gear Does oil GOOD Is electric GOOD Are valves GOOD Does abnormal GOOD Are there any GOOD Are safety GOOD Is air releasing GOOD Is hydraulic GOOD Does oil block GOOD Check hydraulic
does not work leak? motor running? operated perssure rise in obstacles around valves adjusted valve closed? pump tilted? valve change pump
correctly? all cylinders? tiller and ram? correctly? over on-load?
NO GOOD NO GOOD
NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD
Tighten packing Operate valves Check spool Remove it Re-adjust Close it Is solenoid- GOOD Is selector GOOD Is filter GOOD Is orifice or
additional or according to operation of safety valve controlled valve valve stuck? clogged? pilot line
replace packing instruction plate OB valve (Refer to 4.2.10) changed-over? clogged?
NO GOOD NO GOOD NO GOOD NO GOOD
Lapping of Clean filter Clean it

Does starter GOOD Disconnect GOOD Check check valve element
operate? coupling hydraulic pump
NO GOOD NO GOOD
Is solenoid GOOD Is selector GOOD Is filter
NO GOOD
electric source valve stuck? clogged?
Check electric Check electric ON?
source motor
NO GOOD NO GOOD NO GOOD
NO GOOD
NO GOOD NO GOOD NO GOOD
Check Lapping of Replace
control box spool solenoid
Rudder turning Does oil GOOD Are valves GOOD Are there any GOOD Are Safety GOOD Is air releasing GOOD Is pump max. GOOD
speed is slow leak? operated obstacles around valves adjusted valve closed? tilting angle
correctly? tiller and ram? correctly? correct?
NO GOOD
Steering gear Is air contained GOOD Are there any GOOD Is ram packing GOOD Is pump tilting GOOD Check clearance Adjust control box Is servo pressure GOOD Does pump GOOD Does servo piston GOOD Check
does not work in hydraulic obstacles around over tightened? angle unstable? between rudder (Adjust pump max. 1.8-2.0 MPa control unit of hydraulic hydraulic
smoothly circuit? tiller and ram? stock and bearing tilting angle) (18-20 kgf/cm²) move? regulator move? pump
NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD
Release air Remove it Loosen ram Check hydraulic

packing a little regulator
Is abnormal alarm YES Does servo piston

Steering gear Is the ship NO Is proportional GOOD Is clearance of GOOD Is clearance of GOOD Is clearance between GOOD Are valve and air GOOD Check
of torque motor of hydraulic
is unstable at anchor? band adjusted pump control repeat back unit tilier arm and roller releasing valves control box
given? regulator move?
too small? device excessive? lever excessive? bearing excessive? closed securely?
NO GOOD
NO GOOD NO GOOD NO GOOD NO GOOD
NO GOOD
Check
Adjust it Check it or Check it or Check it or control box
Check them or
at 2°-5° replace part replace part replace part
refit them
Abnormal noises Do nises occur NO Do noises occur GOOD Do noises occur GOOD Do abnormal GOOD Investigate Is relief valve GOOD Is line filter GOOD Is servo pump GOOD Check
while ship is whenever rudder from ram from rudder noises from abnormal noises adjusted clogged? abnormal? servo piping
under voyage is worked? packing? carrier? hydraulic pump? source and check it correctly?
YES NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD NO GOOD
Release air Loosen ram Check lubricationg Check hydraulic Re-adjust Clean filter Check servo pump
packing a little condition or consult pump relief valve element
with shipbuilder

S791 M-38 6R5111121 Steering Gear PDF

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

S791 M-38 6R5111121 Steering Gear PDF

Transféré par

Droits d'auteur :

Formats disponibles

20

Service center (CS Team)

Home page : http://www.flute

(Drrawing No. : 00905081F-1)

Installation manual Page 1 of 57 FLU

Warning : indicates a pottentially hazardous situation which, if not avoid

Caution : indicates a pote

Notice : signs used to indicate a statement of company policy directlyy or indirectly

[1] Warnings and Cautions related to operation

WARNING Never ope

Installation manual Page 2 of 57 FLU

[3] Warnings and Cautions for operation

Use the prroper working oil, and maintain the conta

Use the prroduct under the specification mentioned

[4] Warnings related to maintenance

Installation manual Page 3 of 57 FLU

2 Detailed description of main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1.2 Ram and Hydrauliic cylinder ................................. 8

2.1.3 Oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1.4 Oil block valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.1 Construction and name of parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2.2 Principle of operattion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.3 Continuous control syste

3 Instructions for installation .......................................... 19

4 Instructions for adjustment ......................................... 20

4.1 Preparation ................................................. 20

4.1.2 Working oil and filling ..................................... 20

4.1.3 Application of lubrricating oil and grease ....................... 22

4.1.4 aulic pump and electric motor . . . . . . . . . . . . . . . . . .

4.1.5 Inserting of ram V-packing

4.2 Adjustment ............................................... 23

4.2.1 Electric motor starting ................................... 23

4.2.2 Adjustment of serrvo pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2.3 Air release in hydrraulic regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Installation manual Page 4 of 57 FLU

4.2.5 Air release in hydrraulic system ............................... 26

4.2.6 Adjustment of con

4.2.7 aximum pump stroke . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.8 Adjustment of rud

4.2.9 Measurement and

4.2.10 Adjusting test of safety

5.1 Normal steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2 Local steering . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.1 General notes ............................................... 32

6.2 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.3 Detail of check items .......................................... 35

6.3.1 Normal checks ........................................... 35

6.3.2 Before voyage che

6.3.3 Periodical checks (at dock or basin) ............................ 38

6.3.4 Check of working oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.5 Dismantling and assemb

6.6 Dismantling and assemb

6.7 Dismantling procedures for pintle bearing inspection .................... 49

7 Trouble shooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.2 Trouble shooting of stee

7.3 Trouble shooting of valvve, pump and electric motor ..................... 55

8 Service net work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Installation manual Page 5 of 57 FLU

Fig.ルユOIL TANK UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Fig.ヮユOB VALVE (OB15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65